Embedded Rebar Charging Coil Structure for Lower-Cost Concrete Pads
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Solution Overview
Problem
The cost and complexity of installing wireless charging transmitter coils in permanent primary pads, such as concrete slabs, are prohibitive.
Innovation Solution
Embedding a transmitter coil in a reinforced concrete slab using steel rebar and copper clad steel (CCS) wire, which reduces material costs and complexity by utilizing the rebar as part of the coil structure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional transmitter coils are installed in permanent primary pads, then wireless charging functionality is achieved, but installation cost and complexity become prohibitive
Solution Approach 1:
The patent combines the structural reinforcement function (rebar) with the wireless charging transmission function by integrating copper-clad steel wire onto the rebar, creating a dual-purpose component that eliminates separate installation of transmitter coils
Solution Approach 2:
The rebar serves multiple functions: structural reinforcement of concrete, electrical conduction for wireless charging, and magnetic field generation, replacing the need for dedicated transmitter coil assemblies
2Reliability
If traditional transmitter coils are installed in permanent primary pads, then wireless charging functionality is achieved, but installation cost becomes prohibitive
Solution Approach 1:
The rebar serves its own structural purpose while simultaneously functioning as the transmitter coil, eliminating the need for separate expensive transmitter coil installations and reducing overall system cost
Solution Approach 2:
By merging the structural reinforcement role with the wireless charging transmission role into a single integrated component, the patent eliminates redundant materials and installation steps, significantly reducing cost
3Ease of manufacture
If rebar is used as part of the transmitter coil structure, then material cost and complexity are reduced, but structural integrity must be maintained
Solution Approach 1:
The patent uses copper-clad steel wire that combines steel core (for structural strength and magnetic properties) with copper cladding (for electrical conductivity), creating a composite material that satisfies both structural and electrical requirements
Solution Approach 2:
The copper cladding is applied locally on the steel rebar surface where electrical contact is needed, while the steel core maintains structural integrity throughout, optimizing both functions in different regions of the same component
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 lowers installation costs and maintains durability, enabling efficient wireless charging for electric vehicles while maintaining structural integrity.
Implementation Method 1
a transmitter coil (also known as a primary coil) and a receiver coil (also known as a secondary coil) are used to wirelessly transfer electrical power
Data Source
AI summary
A wireless charging primary pad includes a transmitter coil formed from steel rebar and copper clad steel (CCS) wire, and a reinforced concrete slab with transmitter coil is embedded therein. The transmitter coil can be formed from the CCS wire wound around the steel rebar and/or the CCS wire extending from an end of the steel rebar. Also, the reinforced concrete slab can include a magnetizable concrete layer.