Induction Charging Coil Assembly With Gap Flux Filling
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Solution Overview
Problem
Induction charging devices for vehicles face challenges in efficiently guiding magnetic flux and manufacturing complexity due to the need for precise mating of magnetic-flux guiding elements, leading to transmission losses and increased costs.
Innovation Solution
The introduction of a magnetically conductive filling assembly in the gaps between spaced magnetic-flux guiding elements, which can be partially or fully filled with magnetic-flux guiding particles, optimizes magnetic flux guidance and simplifies the manufacturing process by reducing the need for custom-fit surface grinding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If magnetic-flux guiding elements are spaced apart to simplify manufacturing, then manufacturing complexity is reduced, but magnetic flux transmission efficiency deteriorates due to gaps
Solution Approach 1:
A filling assembly comprising magnetically conductive particles and binding agent is introduced as an intermediary substance in the gaps between magnetic-flux guiding elements. This filling assembly bridges the magnetic flux path across the gap, maintaining efficient magnetic coupling while allowing the elements to be manufactured and assembled separately without requiring precision surface grinding.
2Loss of energy
If magnetic-flux guiding elements are custom-fit through surface grinding to eliminate gaps, then magnetic flux transmission efficiency is improved, but manufacturing complexity and cost increase
Solution Approach 1:
The requirement for precision surface grinding and custom-fit mating is extracted from the manufacturing process. Instead of grinding the magnetic-flux guiding elements to achieve tight mating, the invention uses a filling assembly that can be easily applied to standard-sized elements, eliminating the need for laborious and expensive surface grinding operations.
3Loss of energy
If gaps between magnetic-flux guiding elements are reduced to improve magnetic flux density, then manufacturing precision requirements increase
Solution Approach 1:
The invention changes the physical state and properties of the gap region by introducing a filling assembly with specific magnetic permeability characteristics. This allows larger gaps to be tolerated while maintaining effective magnetic flux density, as the filling material provides a continuous magnetic path with controlled magnetic properties.
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 solution enhances magnetic flux transmission efficiency, reduces manufacturing complexity and costs, and allows for higher power transmission capabilities, such as up to 10 kW, while minimizing residual air content and eddy current losses.
Implementation Method 1
at least partly arranging a filling assembly in a gap between two spaced magnetic-flux guiding elements, which filling assembly is at least partly magnetically conductive
Implementation Method 2
at least one coil for the generating or for the receiving of a magnetic alternating field
Data Source
AI summary
An induction charging device is disclosed. The induction charging device includes at least one coil and at least two magnetic-flux guiding elements spaced apart from one another. At least one gap is disposed between the at least two magnetic-flux guiding elements. A filling assembly is at least partially arranged in the at least one gap. The filling assembly is at least partly magnetically conductive. The filling assembly includes a plurality of layers where at least one layer defines a magnetically conductive layer and at least one other layer defines a magnetically neutral layer. The at least one gap has a gap height, a gap width, and a gap length. The filling assembly, in the at least one gap, is defined of different layers with respect to at least one of the gap height and the gap length.