Cross-Laminated Magnetic Core for Eddy Loss and Thermal Uniformity
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Solution Overview
Problem
Inductive power transfer (IPT) systems face challenges in enhancing power transfer efficiency and competitiveness due to limitations in soft magnetic materials, such as low saturation flux density and temperature-dependent properties of soft MnZn ferrites, as well as issues with air gaps in ferrite block assemblies leading to hotspots and instability.
Innovation Solution
The use of laminated cores, specifically combining horizontal and vertical lamination structures with Fe-based nanocrystalline materials and nanocrystalline flake ribbons, respectively, to create a cross-lamination structure that reduces eddy currents, maintains high magnetic permeability, and balances flux density distribution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If soft MnZn ferrites are used in IPT systems, then affordability and sufficient magnetic properties are achieved, but saturation flux density is low and temperature-dependent properties cause instability
Solution Approach 1:
The patent changes the material parameters by transitioning from soft MnZn ferrite to Fe-based nanocrystalline materials, which have fundamentally different magnetic properties including higher saturation flux density and superior thermal stability, thereby resolving the temperature-dependent instability issue while maintaining manufacturing feasibility
Solution Approach 2:
The patent employs composite construction by combining horizontally laminated nanocrystalline cores with vertically laminated nanocrystalline flake ribbons in a cross-lamination structure, creating a hybrid magnetic core that leverages the complementary strengths of different material configurations to achieve both high power density and thermal stability
2Power
If ferrite blocks are assembled to increase power density, then magnetic coupling is improved, but air gaps are introduced causing hotspots and system instability
Solution Approach 1:
The patent segments the magnetic core into multiple thin laminated layers both horizontally and vertically, with insulating coatings on each layer that prevent eddy current formation and eliminate air gap-related hotspots, thereby maintaining high power density without compromising system stability
Solution Approach 2:
The patent introduces a cross-lamination dimension by combining horizontal and vertical lamination structures, creating a three-dimensional magnetic path that eliminates air gaps and distributes magnetic flux uniformly, preventing hotspots while maintaining high power density
3Power
If laminated cores with high permeability materials are used, then saturation flux density and magnetic coupling are improved, but eddy current losses increase due to highly conductive materials
Solution Approach 1:
The patent segments the conductive nanocrystalline material into thin laminated layers separated by insulating coatings, which breaks the eddy current paths and reduces eddy current losses while preserving the high saturation flux density and magnetic coupling properties of the nanocrystalline material
Solution Approach 2:
The patent introduces insulating coatings as intermediary layers between the highly conductive nanocrystalline laminations, which act as barriers to eddy currents while allowing magnetic flux to pass through, thereby reducing energy losses without compromising magnetic performance
4Loss of energy
If horizontally laminated nanocrystalline cores are used, then eddy current losses are reduced, but flux density distribution becomes non-uniform
Solution Approach 1:
The patent creates a composite cross-lamination structure combining horizontal and vertical lamination configurations, where the vertical laminations complement the horizontal ones by providing alternative flux paths that distribute flux density more uniformly across the core while maintaining reduced eddy current losses
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 cross-lamination structure significantly reduces eddy current losses, enhances magnetic coupling efficiency, and improves thermal management, leading to increased power density and efficiency in IPT systems, while also reducing thermal imbalances and extending operational duration.
Implementation Method 1
By utilizing thin laminations, the effective paths for eddy currents along the ribbon directions are reduced, thereby minimizing eddy current losses
Implementation Method 2
a magnetic flux device configured to transmit or receive magnetic flux to or from a space beyond the magnetic flux device
Data Source
AI summary
A magnetic flux device configured to transmit or receive magnetic flux to or from a space beyond the magnetic flux device. The magnetic flux device includes a first electrically conductive coil and a magnetically permeable core. The magnetically permeable core includes a plurality of first laminated cores each laminated along a first direction, and a plurality of second laminated cores each laminated along a second direction substantially perpendicular to the first direction. The combination of the first and second laminations enhances the efficiency as well as thermal uniformity.