Flexible Magnetic Core Structure for EV Inductive Charging
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Solution Overview
Problem
Existing inductive energy emitters/receivers for electric vehicle charging face challenges with brittle rigid magnetic cores that are prone to breakage under the weight and impact of vehicles, and flexible magnetic cores previously proposed are insufficient for managing the energy requirements of fast charging.
Innovation Solution
A flexible planar-shaped magnetic core composed of multiple elongated partial cores made of ferromagnetic materials, connected in an articulated manner or as parallel continuous wires, embedded in a flexible polymer bonded soft magnetic material casing, which absorbs impacts and weight without breaking, enhancing magnetic performance and efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a rigid magnetic core is used, then magnetic performance is improved, but the core is prone to breakage under vehicle weight and impact
Solution Approach 1:
The patent changes the physical state and mechanical properties of the magnetic core material from rigid to flexible through polymer bonding technology. The flexible magnetic core maintains the necessary magnetic permeability and flux conduction capabilities while gaining elasticity and impact resistance, allowing it to withstand vehicle weight and thermal expansion without breaking.
Solution Approach 2:
The patent employs composite material construction by combining magnetic particles or powder with a polymer binder to create a flexible magnetic core. This composite structure integrates the magnetic properties of the magnetic material with the mechanical flexibility and durability of the polymer matrix, resolving the contradiction between magnetic performance and breakage resistance.
2Reliability
If a flexible magnetic core is used, then impact resistance is improved, but energy management capability deteriorates
Solution Approach 1:
The patent optimizes the composition ratios of magnetic particles to polymer binder, and controls the density and permeability parameters of the flexible magnetic core to achieve fast charging capability. By adjusting these parameters, the flexible core can manage high energy transfer rates required for fast charging while maintaining impact resistance.
Solution Approach 2:
The patent applies different material compositions and densities to different regions of the flexible magnetic core to optimize local magnetic flux distribution and energy transfer efficiency. This ensures that the flexible core can effectively manage energy during fast charging while maintaining overall structural flexibility and impact resistance.
3Weight of moving object
If a monolithic rigid core is replaced with flexible core, then weight is reduced, but magnetic flux management capability deteriorates
Solution Approach 1:
The patent uses composite materials with optimized magnetic particle concentration and distribution within the polymer matrix to maintain effective magnetic flux management. The composite structure provides sufficient magnetic permeability and flux conduction pathways despite the reduced density compared to monolithic rigid cores, achieving weight reduction without sacrificing flux management capability.
Solution Approach 2:
The patent creates localized regions of higher magnetic material concentration within the flexible core to establish effective flux pathways. This non-uniform distribution ensures that critical areas maintain strong magnetic properties for effective flux management while the overall core remains lightweight due to the polymer matrix.
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 solution provides a flexible magnetic core that can withstand vehicle impacts and efficiently transmit energy, eliminating the need for heavy shields, thus reducing cost and weight while maintaining magnetic performance similar to a monolithic rigid core.
Implementation Method 1
electric energy is feed to the conductive coil which, in collaboration with the magnetic core or cores, generates a directed magnetic field
Implementation Method 2
said magnetic field induces the generation of an electric current on said conductive coil
Data Source
AI summary
Inductive energy emitter/receiver including a planar-shaped magnetic core with two opposed main surfaces is provided having at least one conductive coil wound around an axis perpendicular to the main surfaces of the planar-shaped magnetic core, said the conductive coil being overlapped to one of the main surfaces of the magnetic core; an inductor casing being attached to the planar-shaped magnetic core and at least one conductive coil. The inductor casing is at least partially made of flexible polymer bonded soft magnetic material, and the planar-shaped magnetic core is a made of a plurality of flexible elongated partial cores, forming a flexible planar shaped magnetic core.