Fiber-Reinforced Ferrite Core for Induction Coil Cracking
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Solution Overview
Problem
The manufacturing of complex ferrite core geometric structures for induction charging systems is hindered by the brittle nature of ferrite materials, leading to potential cracking and degradation of magnetic and inductive properties, which is unfavorable for large and flat coil designs.
Innovation Solution
A fiber-reinforced ceramic ferrite core is used, made from materials like carbon or glass fibers, which are electrically insulated and aligned to prevent cracking, allowing for a stable and efficient induction coil unit with reduced weight and installation space, and integrated into a supporting vehicle structure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional ferrite cores are used in induction charging systems, then the magnetic field guidance function is achieved, but the brittle structure leads to cracking and breaking under mechanical loads
Solution Approach 1:
The patent applies composite materials by combining ferrite ceramic with fiber reinforcement (carbon fibers, glass fibers, or basalt fibers) to create a fiber-reinforced ferrite core. This composite structure provides both the magnetic field guidance properties of ferrite and the mechanical strength and crack resistance of the fiber reinforcement, directly resolving the contradiction between reliability and strength.
2Shape
If complex geometric structures are manufactured using conventional ferrite, then the required magnetic field guidance is achieved, but the manufacturing process becomes extremely difficult and costly
Solution Approach 1:
The fiber-reinforced composite structure enables complex geometric shapes to be manufactured more easily because the fibers provide structural integrity throughout the form, allowing the ferrite to be shaped into complex geometries without the risk of cracking during manufacturing or assembly, thus improving ease of manufacture while maintaining geometric complexity.
Solution Approach 2:
The patent allows for the ferrite core to be divided into multiple segments or components that can be separately manufactured and then assembled using the fiber reinforcement as a bonding or connecting element. This segmentation approach enables complex geometries to be built from simpler parts, reducing overall manufacturing difficulty.
3Shape
If multiple ferrite components are arranged to form complex structures, then the required magnetic field guidance is achieved, but the number of components increases and assembly becomes difficult
Solution Approach 1:
The fiber reinforcement acts as a unifying element that merges multiple ferrite components into a single integrated structure. The fibers can bond ferrite segments together, creating a unified assembly that maintains the required complex geometry and magnetic field guidance while reducing the number of separate components and simplifying assembly procedures.
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 fiber-reinforced ceramic ferrite core enhances the stability and magnetic properties of the coil unit, reducing manufacturing costs and improving efficiency, performance, and service life while minimizing mechanical damage and weight.
Implementation Method 1
the ferrite core is made of a fiber-reinforced ceramic material
Implementation Method 2
a primary induction coil that acts as a charging apparatus, which emits a modulating magnetic field
Implementation Method 3
Ferrite cores 6 are provided to guide the magnetic field lines
Data Source
AI summary
A coil unit for inductive transfer of energy has an induction coil and a ferrite core which cooperates with the induction coil. The ferrite core is produced from a fiber reinforced ceramic material. A motor vehicle is equipped with such a coil unit.