Ferrite Bar Magnetic Structure for Wireless Charging
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Solution Overview
Problem
Existing wireless charging systems for vehicles face inefficiencies in magnetic coupling between the primary and secondary coils, leading to suboptimal energy transfer and requiring larger coil sizes to compensate for misalignment tolerances.
Innovation Solution
Incorporating ferrite bars positioned on both sides of the secondary coil to channel and direct magnetic flux through angled windows, enhancing magnetic coupling and efficiency while maintaining a compact design.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If larger coil sizes are used to compensate for misalignment tolerances, then magnetic coupling is improved, but device size increases
Solution Approach 1:
Ferrite bars are introduced as intermediary materials between the primary and secondary coils to channel and concentrate magnetic flux. These ferrite components act as magnetic conductors that guide the magnetic field from the base plate coil to the vehicle plate coil, improving coupling efficiency without requiring larger coil dimensions. The ferrite bars are positioned to bridge the air gap and provide a preferred magnetic path.
Solution Approach 2:
The patent modifies the magnetic properties of the system by introducing ferrite materials with high permeability between the coils. This changes the magnetic circuit parameters, reducing magnetic reluctance and increasing flux density in the coupling region. The ferrite bars alter the magnetic field distribution to concentrate flux where needed, achieving better coupling with compact coil sizes.
2Productivity
If ferrite bars are added to channel magnetic flux, then energy transfer efficiency is improved, but device complexity increases
Solution Approach 1:
The ferrite component is divided into multiple separate bars rather than using a single complex piece. Each ferrite bar is positioned independently to channel magnetic flux through specific paths. This segmentation simplifies manufacturing and assembly while maintaining the flux-channelling function. The modular ferrite bars can be independently positioned and adjusted.
Solution Approach 2:
The ferrite bars serve as intermediary elements that mediate the magnetic coupling between the primary and secondary coils. By introducing these passive magnetic conductors, the system achieves improved energy transfer without requiring active control mechanisms or complex electronic components, thus avoiding excessive complexity.
3Reliability
If ferrite is positioned on both sides of the secondary coil, then magnetic flux guidance is improved, but manufacturing complexity increases
Solution Approach 1:
The ferrite structure is segmented into multiple bars that can be independently manufactured and positioned. The first ferrite bar is placed in a first window and the second ferrite bar is placed in a second window of the secondary coil assembly. This segmentation allows for simplified manufacturing of individual components and easier assembly through standardized positioning features.
Solution Approach 2:
Ferrite bars are strategically positioned in specific windows on opposite sides of the secondary coil where magnetic flux concentration is most beneficial. This local placement optimizes flux guidance at critical locations rather than requiring uniform ferrite coverage throughout the entire structure, reducing material usage and assembly complexity.
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 configuration increases the magnetic coupling between the primary and secondary coils, improving energy transfer efficiency and allowing for more variability in vehicle positioning during charging, thus enhancing overall charging performance without increasing the package size.
Implementation Method 1
The at least one ferrite is arranged to guide the magnetic flux from the bottom side of the at least one second side to the top side of the at least one second side and back to the bottom side of the at least one second side
Implementation Method 2
The first base plate includes at least one first coil for transmitting magnetic flux
Data Source
AI summary
In at least one embodiment, an inductive charging coil assembly for a vehicle comprising a first base plate and a second base plate is disclosed. The first base plate includes at least one first coil for transmitting magnetic flux. The second base plate includes at least one second coil having a top side and a bottom side to receive the magnetic flux for charging a vehicle. The at least one second coil defines a window to position at least one ferrite on the top side and on the bottom side of the at least one second coil. The at least one ferrite is arranged to guide the magnetic flux from the bottom side of the at least one second side to the top side of the at least one second side and back to the bottom side of the at least one second side.