Flexible Coaxial Cable Structure for Low-Loss Inductive Charging
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Solution Overview
Problem
Existing coaxial cables for high-frequency applications, such as inductive charging of electric vehicles, are complex in construction, expensive to produce, and have high power dissipation due to the skin effect and proximity effect.
Innovation Solution
A coaxial cable design featuring a non-conductive core surrounded by a first flexible copper conductor as the inner conductor, an insulation layer, a second flexible copper conductor as the outer conductor, and optional shielding, which reduces power dissipation and increases flexibility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If enameled individual wires are used to reduce skin effect and proximity effect, then power transmission capability is improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The cable is divided into multiple segments: non-conductive core, first flexible copper conductor (inner conductor), insulation layer, and second flexible copper conductor (outer conductor). This segmentation allows each layer to perform its specific function optimally, reducing overall power dissipation while maintaining manageable complexity through modular design
Solution Approach 2:
The cable employs composite construction combining different materials: copper conductors for electrical conduction, non-conductive core and insulation layers for electrical isolation and mechanical support. This composite structure optimizes electrical performance by reducing skin effect and proximity effect while managing the complexity through material property differentiation
2Ease of operation
If conventional litz-wire conductors are used, then flexibility is improved, but power dissipation increases due to skin effect and proximity effect
Solution Approach 1:
Different regions of the cable are assigned different properties: the inner and outer copper conductors provide flexibility and conduction, while the non-conductive core and insulation layers provide electrical isolation. This local differentiation reduces skin effect and proximity effect, lowering power dissipation while maintaining overall cable flexibility
Solution Approach 2:
The non-conductive core and insulation layers act as intermediaries between the copper conductors, providing electrical isolation that reduces proximity effect. These intermediary layers enable the cable to achieve both flexibility from the copper conductors and reduced power dissipation through effective electromagnetic field separation
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 coaxial cable achieves reduced power dissipation and increased flexibility compared to conventional litz-wire conductors, enabling efficient high-frequency power transmission with lower heating and improved installation ease.
Implementation Method 1
During the transmission of alternating signals, such as, for example, alternating current, the current in the conductor cross-section is displaced to the conductor surface by internal magnetic fields as the frequency increases. This effect is known as the skin effect.
Implementation Method 2
In order to reduce the skin effect and/or the so-called proximity effect, which is due to a displacement of current between two closely adjacent conductors
Implementation Method 3
The charging arrangement can be arranged on the ground and comprises inductors. The vehicle can then be inductively charged in the known manner by being placed/moved onto the charging arrangement.
Data Source
AI summary
A coaxial cable includes a non-conductive core and a first flexible copper conductor which surrounds the non-conductive core and is used as an inner conductor of the coaxial cable. Insulation is provided around the first flexible copper conductor. A second flexible copper conductor which surrounds the insulation and serves as an outer conductor of the coaxial cable.