Ground-Pad Sensor Foil for Wireless EV Object Detection
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Solution Overview
Problem
State-of-the-art ground-pad modules for wireless electric vehicle charging lack effective detection methods for metal and living objects close to the charging area, posing risks of heating or burning, and existing sensor arrangements on printed circuit boards (PCBs) are inflexible and difficult to integrate.
Innovation Solution
A flexible sensor arrangement using a foil substrate with printed silver or copper ink sensors and connection cables, integrated into the ground-pad module, which provides enhanced object detection capabilities and is more robust against accidental damage from vehicles.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If state-of-the-art ground-pad modules use field-based detection methods with detection coil arrays or PCB sensor arrangements, then object detection capability is provided, but the sensor arrangements are inflexible and difficult to integrate into the ground-pad module
Solution Approach 1:
The patent applies this principle by replacing rigid PCB-based sensor arrangements with flexible foil substrates that can be conformally integrated into the ground-pad module. The thin film nature of the foil allows it to be placed in various configurations and positions, providing integration flexibility while maintaining sensor functionality for detecting metal and living objects.
Solution Approach 2:
The patent replaces the mechanical PCB structure with a flexible foil-based system. This substitution eliminates the rigidity and complexity associated with PCB mounting, routing, and integration, while providing a simpler, more adaptable sensor arrangement that can be easily integrated into the ground-pad module structure.
2Object-affected harmful factors
If ground-pad modules lack effective object detection means, then device complexity is reduced, but the risk of heating or burning from metal or living objects increases
Solution Approach 1:
The patent applies this principle by designing a sensor arrangement that can detect both metal objects and living objects using the same foil-based platform. The flexible foil substrate supports multiple sensor types and configurations, providing universal detection capability that addresses multiple safety concerns (heating of metal objects and burning of living objects) with a single integrated system, rather than requiring separate detection systems for each hazard.
Solution Approach 2:
The flexible foil acts as an intermediary substrate that enables safe and effective object detection. It provides a platform for mounting detection sensors that can identify both metal and living objects, thereby mediating between the power emission system and the safety requirements, allowing the system to detect potential hazards and prevent heating or burning without requiring complex separate detection systems.
3Reliability
If rigid PCB sensor arrangements are used, then manufacturing precision is maintained, but the sensor arrangement is vulnerable to accidental damage from vehicles
Solution Approach 1:
The patent applies this principle by using flexible foil substrates instead of rigid PCBs for the sensor arrangement. The flexibility of the foil makes it inherently more resistant to accidental damage from vehicles, as it can deform without breaking rather than shattering like rigid PCB material. This improves reliability while the foil can still be manufactured with appropriate precision through standard flexible circuit board techniques.
Solution Approach 2:
The patent changes the physical parameter of the sensor substrate from rigid (PCB) to flexible (foil). This parameter change fundamentally alters the damage resistance characteristics, making the sensor arrangement more tolerant of mechanical stress and accidental impacts from vehicles, while still maintaining manufacturability through established flexible circuit fabrication 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 flexible sensor arrangement on a foil substrate improves object detection sensitivity and integration within the ground-pad module, reducing the risk of heating or burning from metal or living objects and allowing for more flexible placement, while maintaining effective power emission functionality.
Implementation Method 1
the GPM is configured to inductively transmit electric power from the GPM to the CPM... sensor arrangement configured for conducting at least one of a sensing current, a measuring-induced current, and voltage
Implementation Method 2
the GPM is configured to inductively transmit electric power from the GPM to the CPM comprised by the electric vehicle and configured to charge the battery
Data Source
AI summary
A ground-pad module (GPM) for wirelessly charging a battery in an electric vehicle. The GPM includes a power emission device that is configured to provide electric power to a car-pad module (CPM) provided by the electric vehicle and configured to charge the battery. The GPM inductively transmits electric power from the GPM to the CPM, and a sensor arrangement for detecting at least one of objects made at least partly from metal, living objects, and a relative positioning between the CPM and the GPM. The sensor arrangement is configured to conduct at least one of a sensing current, a measuring-induced current, and voltage. The sensor arrangement includes a foil as base substrate, a plurality of sensors and connection cables printed on the foil, which sensors are configured to provide object detection.