Contoured Ferromagnetic Shield for Inductive Power Transfer Flux Control
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Inductive power transfer systems often waste magnetic flux as it passes through components other than the receiving coil, leading to heat dissipation and potential damage, reducing the efficiency and safety of wireless charging.
Innovation Solution
A contoured shield made from high magnetic permeability materials, such as iron or doped polymers, is applied to both transmit and receive coils to redirect magnetic flux efficiently between the coils, minimizing flux loss and heat generation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If inductive power transmitter transmits power through magnetic flux, then power transfer is achieved, but magnetic flux passes through and disturbs other components causing heat dissipation and power loss
Solution Approach 1:
A shield made of high magnetic permeability material is introduced as an intermediary component between the transmit coil and surrounding components. This shield captures and redirects magnetic flux that would otherwise pass through and disturb other components, channeling it back toward the receive coil. The shield acts as a flux director, reducing power loss and heat dissipation by preventing magnetic flux from interacting with harmful components.
Solution Approach 2:
The magnetic permeability parameter of the shield material is specifically selected to be high, which enables efficient capture and redirection of magnetic flux. By changing the magnetic permeability parameter of the intervening material, the system optimizes flux distribution, reduces energy loss, and minimizes heat generation in surrounding components.
2Productivity
If magnetic flux is directed more efficiently, then power transfer efficiency improves, but system complexity increases due to additional shield components
Solution Approach 1:
The shield is segmented into multiple components, each serving a specific function in different regions around the coil assembly. This segmentation allows for optimized flux control in different areas while keeping each individual shield component relatively simple. The segmented approach maintains high power transfer efficiency without requiring a single complex shield structure.
3Loss of energy
If shield material with high magnetic permeability is used, then flux concentration improves, but manufacturing cost and material selection complexity increase
Solution Approach 1:
The shield utilizes composite material structures that combine high magnetic permeability properties with manufacturable forms. By using composite materials, the system achieves effective flux concentration and redirection while maintaining ease of manufacturing. The composite approach allows for cost-effective production of shields with the necessary magnetic properties.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The contoured shield significantly enhances the power transfer efficiency by directing magnetic flux directly between the transmit and receive coils, reducing heat dissipation and protecting electronic components from flux interference.
Implementation Method 1
A contoured shield made from high magnetic permeability materials, such as iron or doped polymers, is applied to both transmit and receive coils to redirect magnetic flux efficiently between the coils
Implementation Method 2
a transmitting coil within the transmitter may produce a time-varying magnetic flux that may induce a current within a receiving coil within the electronic device
Data Source
AI summary
Methods of and systems for directing flux from a transmit coil to a receive coil within an inductive power transfer system are disclosed. For example, a transmit coil can be shielded with a contoured shield made from a ferromagnetic material. The contoured shield contours to several surfaces of the transmit coil so as to define a single plane through which magnetic flux is directed to a receive coil.