Frustoconical Inductive Charging Coils With Self-Aligning Locking
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Solution Overview
Problem
Existing inductive charging systems lack efficient alignment mechanisms for coils, leading to flux leakage and misalignment issues, and there is a need for a releasable and locking mechanism to facilitate easy mating of frustoconical coils.
Innovation Solution
The use of a frustoconical coil pair with a male-female connection and a locking mechanism, where one coil is housed within the other, ensuring easy alignment and minimizing flux leakage through a spindle and ball system.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional inductive charging coils are used without special alignment mechanisms, then the device complexity is reduced, but flux leakage increases and alignment precision deteriorates
Solution Approach 1:
The transmitter coil is nested within a frustoconical housing that receives the receiver coil, creating a nested arrangement where the receiver coil fits inside the transmitter coil's frustoconical space. This nesting structure provides automatic alignment and centering of the coils, improving alignment precision while containing the alignment mechanism within the existing coil structures.
Solution Approach 2:
The frustoconical shape of both the transmitter and receiver coils provides curved surfaces that facilitate automatic alignment when the coils are brought together. The conical geometry creates a natural centering effect as the coils mate, eliminating the need for complex mechanical alignment mechanisms while ensuring precise coil positioning.
2Loss of energy
If frustoconical coil pair with locking mechanism is used, then alignment precision and flux containment are improved, but device complexity increases
Solution Approach 1:
The receiver coil is nested within the transmitter coil's frustoconical housing, creating a tight fit that contains the magnetic flux within the coil assembly. This nested arrangement prevents flux leakage to the surrounding environment while maintaining a relatively simple overall structure that integrates the alignment and containment functions.
Solution Approach 2:
The frustoconical shape introduces asymmetry to the coil structures, with the tapered geometry providing directional alignment and flux containment. The asymmetric conical surfaces guide the coils into proper alignment and create a focused magnetic field pattern that reduces flux leakage compared to symmetric cylindrical designs.
3Reliability
If frustoconical coils with locking mechanism are used, then connection reliability is improved, but ease of operation deteriorates
Solution Approach 1:
The frustoconical geometry of the transmitter and receiver coils enables self-alignment and self-centering when the components are brought together. The tapered surfaces automatically guide the coils into proper alignment and the locking mechanism engages automatically through the spindle and recess interaction, eliminating the need for manual alignment operations while ensuring reliable connection.
Solution Approach 2:
The curved frustoconical surfaces provide smooth guidance during the mating process, allowing the coils to align through their tapered geometries without requiring precise manual positioning. The curved surfaces facilitate easy insertion while the integrated locking mechanism secures the connection, balancing ease of operation with connection reliability.
4Productivity
If conventional cylindrical coils are used, then manufacturing is simpler, but alignment efficiency and flux containment are reduced
Solution Approach 1:
The frustoconical shape of the coils creates a tapered geometry that focuses the magnetic flux along the axis of the cone, improving charging efficiency by directing the magnetic field where it is needed. The curved conical surfaces also provide automatic alignment during mating, ensuring optimal flux coupling between transmitter and receiver coils while maintaining manufacturing feasibility through standard forming processes.
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 frustoconical coil design enhances alignment efficiency, reduces flux leakage, and provides a secure locking mechanism, resulting in improved charging efficiency and reduced electromagnetic interference.
Implementation Method 1
an inductive charging station that includes a frustoconical transmitter coil and an LEV with a frustoconical receiver coil that nests in the frustoconical transmitter coil
Data Source
AI summary
A pair of coils for use in inductive charging of a light electric vehicle, the pair of coils comprising a first frustoconical coil and a second frustoconical coil, wherein the first frustoconical coil defines an interior which is sized to accept the second frustoconical coil.