Induction Charging Coil Structure With Unground Core Plates
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Solution Overview
Problem
Conventional induction charging systems for electric vehicles face high manufacturing costs due to the need for precision grinding of core plates to minimize tolerances and maintain resonance, which is inefficient and costly.
Innovation Solution
The core plates are arranged vertically between the coil strands and a supporting structure, with at least one unground surface zone, allowing precise alignment and reduced manufacturing costs while maintaining inductive efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If precision grinding is applied to core plates to minimize tolerances and maintain resonance, then manufacturing precision is improved, but manufacturing cost increases
Solution Approach 1:
The patent applies local quality by differentiating the surface treatment of core plates based on functional requirements. Only specific contact surfaces that require precise alignment with coil strands undergo grinding, while other surfaces retain their original sintered finish. This selective approach maintains necessary precision at critical interfaces while eliminating unnecessary grinding operations, thereby reducing manufacturing costs without compromising resonance performance.
2Use of energy by moving object
If core plates are positioned close to coil strands to maximize inductive efficiency, then energy transfer efficiency is improved, but mechanical stability deteriorates
Solution Approach 1:
The patent resolves the conflict between proximity and stability by introducing a vertical dimension for positioning. Core plates are arranged in multiple vertical layers at different heights relative to the coil strands, rather than being positioned only in the horizontal plane. This multi-layer vertical arrangement allows sufficient close proximity for efficient inductive coupling while maintaining adequate mechanical spacing and structural stability through the vertical distribution of components.
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
This configuration ensures minimal variance in inductive properties, reduces manufacturing costs, and enhances mechanical stability, enabling efficient energy transfer without deformation or damage.
Implementation Method 1
electrical energy can be transferred from the stationary induction charging device to the mobile induction charging device by means of induction, i.e. via an electromagnetic alternating field
Implementation Method 2
the electromagnetic alternating field generated by the respective coil, which is also radiated downwards by the respective coil, is deflected upwards, thereby quasi-amplifying the alternating field radiated upwards
Data Source
AI summary
An induction charging device for an inductive vehicle charging system for charging a battery of a battery-powered electric vehicle is disclosed. The induction charging device includes at least one coil for generating an electromagnetic alternating field and a coil carrier structure composed of plastic for positioning the strands. A supporting structure is arranged below the at least one coil in a vertical direction. The supporting structure has a plurality of supporting elements arranged at a distance from one another in a longitudinal direction perpendicular to the vertical direction and supported in the vertical direction on the coil carrier structure. At least two magnetic field conducting core plates composed of a soft magnetic material for conducting magnetic flux are provided and have at least one unground surface section. The core plates are supported in the vertical direction on at least one supporting element.