Embedded PCB Rectifier Layout for Low-Profile EV Wireless Charging
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Solution Overview
Problem
Conventional rectifiers for wireless power transfer in electric vehicles (EVs) are bulky due to the use of large components like capacitors and inductors, leading to space constraints in EVs, which limits the adoption of wireless charging systems.
Innovation Solution
The design employs embedded printed circuit board (PCB) technology to create a compact low-profile rectifier by separating inductance and power loop components, using an 8-layer PCB for inductors and a metal PCB for thermal dissipation, with ferrite cores minimized to reduce thickness and allow more space for inductors, and integrating components directly into the PCB without packaging to reduce volume.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional rectifiers use bulky components like capacitors and inductors, then the rectifier can perform wireless power transfer, but the total volume of the rectifier becomes large
Solution Approach 1:
The patent transitions from three-dimensional bulky components to two-dimensional planar structures by implementing inductors as PCB trace windings and embedding all components within the PCB layers. This dimensional reduction eliminates the need for external capacitors and inductors, achieving a flat-profile rectifier that maintains wireless power transfer functionality while dramatically reducing volume.
Solution Approach 2:
The patent merges multiple discrete components (capacitors, inductors, rectifier diodes) into a single integrated PCB structure. The inductors are formed directly on the PCB using copper traces, and all components are embedded within the PCB layers, combining what were previously separate bulky components into one compact unit.
2Length of stationary object
If ferrite cores are minimized to reduce thickness, then the rectifier profile becomes lower, but space for inductors is reduced
Solution Approach 1:
The patent resolves this contradiction by moving the inductor function from external three-dimensional components to two-dimensional PCB trace windings. The inductors are formed by copper traces on the PCB itself, eliminating the need for vertical space that would traditionally be occupied by ferrite cores and external inductor components.
Solution Approach 2:
The PCB serves multiple functions simultaneously: it provides the structural substrate, contains the inductor windings through copper traces, embeds all electronic components, and provides thermal management pathways. This multi-functionality eliminates the need for separate ferrite core components, achieving thinness without sacrificing inductor space.
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
This approach results in a rectifier that is 75% thinner, enabling more efficient use of space, improved thermal performance, and higher power density, facilitating easier integration with other EV components and faster charging capabilities.
Implementation Method 1
One or more ferrite blocks may be assembled into the PCB
Implementation Method 2
Fabricating an inductor area in the PCB, wherein each component of the power device area, the passive component area, and copper windings of the inductor area may be entirely embedded within the PCB
Implementation Method 3
A cold plate may be attached to a bottom copper layer of the PCB
Data Source
AI summary
A method, computer program product, and apparatus for a rectifier. The rectifier may be fabricated, wherein fabricating the rectifier may include fabricating a power device area in a printed circuit board (PCB). Fabricating the rectifier may include fabricating a passive component area in the PCB. Fabricating the rectifier may include fabricating an inductor area in the PCB, wherein each component of the power device area, the passive component area, and copper windings of the inductor area may be entirely embedded within the PCB. One or more ferrite blocks may be assembled into the PCB.