Vehicle Inductive Charging Coil With Segmented Ferrite Cores
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Solution Overview
Problem
The inefficiency of inductive charging systems for vehicles due to the limited absorption of the magnetic field by the secondary coil, resulting in reduced charging power and efficiency.
Innovation Solution
A receiving coil arrangement featuring a combination of outer and inner ferrite cores with different shapes and air gaps, along with non-ferromagnetic connecting materials, allows for the efficient capture and conversion of both vertical and horizontal magnetic field components into electrical current, enhancing the charging efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If a conventional single-coil receiving arrangement is used, then the device complexity is low, but the charging efficiency is reduced due to limited magnetic field absorption
Solution Approach 1:
The receiving coil arrangement is segmented into multiple independent coils (first receiving coil and second receiving coil) with different orientations. The first receiving coil is wound around the first ferrite core in the longitudinal direction, while the second receiving coil is wound helically around the second ferrite core. This segmentation allows each coil to capture different components of the magnetic field, improving overall energy absorption efficiency.
Solution Approach 2:
The invention introduces spatial dimensionality by arranging receiving coils in different orientations and directions. The first receiving coil captures magnetic field components along the longitudinal direction, while the second receiving coil captures components in the radial direction through helical winding. This multi-dimensional arrangement enables comprehensive coverage of the magnetic field vector, converting more magnetic field energy into electrical current.
2Loss of energy
If ferrite cores are used to enhance magnetic field reception, then the magnetic field absorption efficiency is improved, but the weight of the receiving coil arrangement increases
Solution Approach 1:
The invention uses ferrite cores as magnetic shielding and concentrating materials to enhance magnetic field reception. The first ferrite core and second ferrite core are strategically positioned and shaped to guide and concentrate magnetic field lines toward the respective receiving coils, significantly improving magnetic field absorption efficiency while the ferrite material's high permeability ensures effective magnetic flux concentration.
Solution Approach 2:
The ferrite cores are designed with specific local geometries optimized for their functions. The first ferrite core has a shape optimized for longitudinal magnetic field reception, while the second ferrite core is shaped for radial field reception. This local optimization ensures that each ferrite core efficiently handles the specific magnetic field components in its region, maximizing overall absorption efficiency.
3Loss of energy
If air gaps are introduced in ferrite cores, then magnetic short circuits are prevented and efficiency is improved, but the manufacturing precision requirements increase
Solution Approach 1:
Air gaps are intentionally extracted or introduced into the ferrite core structures at specific locations. The first air gap is positioned in the first ferrite core, and the second air gap is positioned in the second ferrite core. These air gaps serve to magnetically decouple the ferrite cores, preventing magnetic short circuits and improving the overall charging efficiency by ensuring that magnetic flux passes through the receiving coils rather than short-circuiting through the ferrite cores.
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 enables a higher percentage of the transmitted magnetic field to be converted into electrical current, leading to more efficient inductive charging of vehicle batteries.
Implementation Method 1
The primary coil, which is energized, generates a magnetic field with a transmission power, which is received by the secondary coil and converted into charging current with a charging power
Implementation Method 2
The receiving coil arrangement comprises a first ferrite core and a second ferrite core
Data Source
Figure 1~6
Figure 7~9
AI summary
The invention relates to a vehicle inductive charging device having a receiving coil assembly (SA1, SA2, SA3, SA4, SA5, SA6) for inductively charging a vehicle, wherein the receiving coil assembly (SA1, SA2, SA3, SA4, SA5, SA6) comprises: an outer ferrite core (FK1), which is shaped so as to extend around an area (FL); an inner ferrite core (FK2), which is physically connected to the outer ferrite core (FK1) by means of at least one joint (VS) and extends in the area (FL) from said joint (VS) out.