Honeycomb Multi-DD Coil Layout for Misalignment-Tolerant Power Transfer

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Solution Overview

Problem

Conventional coil designs for wireless power transfer systems face challenges in achieving high coupling and misalignment tolerance, particularly in mid and high-power applications, with honeycomb coil arrays experiencing flux cancellation and requiring complex switching control.

Innovation Solution

A honeycomb multi-DD coil design is introduced, featuring a wire wound to form DD sub-coils with specific current directions, arranged in a honeycomb structure to eliminate flux cancellation and enhance magnetic coupling, using a series-series compensation topology for efficient power transfer.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Loss of energy

If conventional honeycomb coil arrays are used, then power transfer capability is provided, but flux cancellation occurs and complex switching control is required

Engineering Contradiction:

Improveflux cancellationVSAvoidswitching control

Core Design Contradiction:

Loss of energyVSDevice complexity

Solution Approach 1:

The coil is segmented into multiple double-D (DD) sub-coils arranged in a honeycomb pattern, where each sub-coil is independently configured to prevent flux cancellation. This segmentation allows each sub-coil to contribute constructively to the overall magnetic field without the cancellation effects seen in conventional honeycomb arrays.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The current flow directions in adjacent DD sub-coils are inverted relative to conventional designs. By configuring adjacent sub-coils with opposite current directions, the magnetic fields add constructively rather than canceling, eliminating the flux cancellation problem inherent in traditional honeycomb coil arrays.

Inventive Principle:

Principle #13The other way round (Inversion)

2Reliability

If conventional coil designs are used, then power transfer is enabled, but coupling factor and misalignment tolerance are limited

Engineering Contradiction:

Improvemagnetic couplingVSAvoidmisalignment tolerance

Core Design Contradiction:

ReliabilityVSAdaptability or versatility

Solution Approach 1:

The transmitter and receiver coils are both segmented into honeycomb patterns of DD sub-coils. This segmentation creates multiple magnetic coupling paths between transmitter and receiver, increasing the overall coupling factor and providing redundancy that improves misalignment tolerance.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The honeycomb arrangement of multiple DD sub-coils creates a three-dimensional magnetic field distribution that is more robust to misalignment. The hexagonal geometry provides multiple overlapping flux paths in different spatial dimensions, maintaining coupling effectiveness even when coils are misaligned.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

3Loss of energy

If conventional coil designs are used, then power transfer is achieved, but leakage flux is higher

Engineering Contradiction:

Improveleakage fluxVSAvoidpower transfer efficiency

Core Design Contradiction:

Loss of energyVSProductivity

Solution Approach 1:

By inverting the current directions in adjacent DD sub-coils, the magnetic fields from neighboring sub-coils reinforce each other rather than cancel, concentrating the magnetic flux in the desired transfer path and reducing leakage flux to the surrounding environment.

Inventive Principle:

Principle #13The other way round (Inversion)

Solution Approach 2:

The magnetic fields from multiple DD sub-coils are merged constructively through the inverted current configuration, creating a unified and concentrated magnetic flux pattern that reduces leakage and improves power transfer efficiency.

Inventive Principle:

Principle #5Merging (Combining)

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 design achieves improved coupling factor, higher power transfer distance, increased misalignment tolerance, reduced leakage flux, and simplified control components, suitable for high-power applications.

Implementation Method 1

A magnetic field is created when current passes through the plurality of DD sub-coils

Methodology Applied

Scientific EffectElectromagnetic induction: Electromagnetic Induction

Data Source

PatentUS12483071B2Honeycomb multi-DD coil design for wireless power transfer systems

Publication Date: 2025.11.25 UT BATTELLE LLC

AI summary

A coil, comprising: a wire wound to form a plurality of double-D (DD) sub-coils, each said DD sub-coil having a plurality of sides defining one of a plurality of hexagonal shaped segments arranged to define a honeycomb structure; wherein a magnetic field is created when current passes through the plurality of DD sub-coils, the plurality of DD sub-coils being configured so that when activated the current flows in a same first direction through adjacent sides of first and second ones of the plurality of DD sub-coils, flows in a same second direction through adjacent sides of first and third ones of the plurality of DD sub-coils, and flows in a same third direction through adjacent sides of the second and third ones of the plurality of coils.