Inductive Energy Transfer Module with Nested Insulation
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Solution Overview
Problem
Inductive charging systems face design complexity due to the need for long creepage distances to ensure safety with high voltages, which is impractical given the close proximity of components in inductive charging devices.
Innovation Solution
A module for inductive energy transfer with a main coil completely enclosed by electrical insulation, where only two connections are routed from/to the coil, and high-voltage and low-voltage parts are separately insulated, allowing for compact design while preventing leakage currents.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If long creepage distances are used to ensure safety with high voltages, then safety regulations are met, but device complexity and space requirements increase significantly
Solution Approach 1:
The patent applies nesting by placing the high-voltage main coil inside a housing made of insulating material. This nested structure provides the required creepage distance internally within the housing walls, allowing the external dimensions to remain compact while meeting safety requirements. The insulation IS1 completely encloses the main coil HS, creating a nested configuration that resolves the contradiction between safety distance and compact design.
Solution Approach 2:
The patent uses a housing made of insulating material that acts as a flexible shell enclosing the high-voltage components. This shell provides the necessary creepage distance through its wall thickness while maintaining a compact external form factor. The insulation IS1 functions as a protective shell that enables safe high-voltage operation without requiring excessive external dimensions.
2Reliability
If long creepage distances are used for high-voltage insulation, then leakage current prevention is improved, but the physical dimensions of the device increase
Solution Approach 1:
The high-voltage main coil is nested within an insulating housing, allowing the creepage distance to be achieved through the housing wall thickness rather than through increased external dimensions. This nested arrangement prevents leakage currents while maintaining compact physical size.
Solution Approach 2:
The patent transitions the creepage distance requirement from a two-dimensional surface distance to a three-dimensional path through the insulating material. By routing connections through the housing walls and using the housing thickness as the insulation path, the effective creepage distance increases without proportionally increasing the external footprint of the device.
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 solution enables a compact and space-saving design that adheres to safety regulations by completely enclosing high-voltage conducting parts, preventing creepage currents and allowing for the implementation of high-voltage and low-voltage components in close proximity.
Implementation Method 1
Inductive charging devices for wireless charging of an energy storage device on the vehicle transfer electrical energy, typically via a resonant magnetic field, wirelessly from a primary unit (GPM or Ground Pad Module)
Implementation Method 2
The term creepage distance here is understood to be the shortest distance between two conductive parts along a surface of a solid insulating material. The term creepage current here is understood to be leakage current which flows along the surface of an insulating material.
Data Source
AI summary
A module for inductive energy transfer, including: a main coil HS enclosed by insulation IS1, with electrical connections A1HS and A2HS routed from/to coil HS by insulation IS1; and an assembly with high-voltage parts HT1 and HT2, and a low-voltage part NT, part HT1 enclosed by insulation IS2HT1 and part HT2 enclosed by insulation IS2HT1 separate from insulation IS2HT2, a connection A1HT routed to a first connection of coil HS, a first electrical supply routed from part NT to part HT1 by insulation IS2HT1, a connection A2HT routed to a second connection of coil HS, and a second electrical supply routed from part NT to part HT2 by insulation IS2HT2, wherein connections A1HS-A1HT are electrically connected and enclosed by insulation IS3A1 that is in contact with insulations IS1 and IS2HT1, and connections A2HS-A2HT are electrically connected and enclosed by insulation IS3A2 that is in contact with insulations IS1 and IS2HT2.