Inductive Power Transfer Assembly with Magnetic Latch and Isolation Switch
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Solution Overview
Problem
Existing power transfer systems for vehicles and devices lack efficient and safe methods for charging batteries while maintaining electrical isolation and ensuring optimal battery life, especially during extended periods of non-use.
Innovation Solution
A power transfer assembly with a portable cable assembly and a receptacle that uses magnetic attraction for secure connection, electrical isolation, and feedback signals to control power transfer, featuring a plug with a power switch and a receptacle with an isolation switch to prevent battery discharge when not charging, and a power converter that adjusts charging voltage based on temperature.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a mechanical and electrical connection is used to charge the battery, then power transfer is reliable, but the vehicle cannot move away freely and the connection is cumbersome
Solution Approach 1:
The patent replaces the traditional mechanical and electrical plug-socket connection with an inductive coupling system using two coils. The first coil in the charging device generates a magnetic field that induces current in the second coil in the vehicle, transferring power wirelessly. This eliminates the need for physical connectors while maintaining reliable power transfer through electromagnetic induction.
2Strength
If the plug and receptacle are held together strongly, then connection is secure, but the vehicle cannot move away when connected
Solution Approach 1:
The patent eliminates mechanical fastening mechanisms entirely by using inductive coupling. The two coils are positioned close together for efficient magnetic coupling, but no physical attachment is required. The vehicle can move away freely while maintaining the magnetic field coupling, as the electromagnetic interaction does not require mechanical strength.
3Reliability
If the vehicle is connected to an external power source, then the battery can be charged, but the battery may discharge through the connection when not in use
Solution Approach 1:
The patent incorporates control circuitry that monitors the charging status and connection state. When the vehicle is not actively charging, the system detects this condition and isolates the battery from the external power source connection, preventing parasitic discharge. The feedback mechanism ensures the battery is only connected when power transfer is actively required.
4Power
If direct electrical connection is used for power transfer, then power transfer is efficient, but electrical isolation and safety are compromised
Solution Approach 1:
The patent introduces a magnetic field as an intermediary between the power source and the battery. The two coils couple magnetically to transfer power without direct electrical contact. This intermediate magnetic coupling maintains high power transfer efficiency while providing inherent electrical isolation and galvanic separation, eliminating safety hazards associated with direct electrical connections.
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
Ensures safe and efficient battery charging with electrical isolation, preventing battery discharge when not in use and optimizing charging voltage for temperature conditions, thus maintaining battery health and extending its service life.
Implementation Method 1
The plug and the receptacle of the power transfer assembly are held together by magnetic attraction when connected
Implementation Method 2
The plug and receptacle of the power transfer assembly are electrically isolated and rely upon magnetic coupling to transfer power and signals
Data Source
AI summary
Apparatus for transferring power to through an isolated, insulated connection. A power transfer assembly includes a portable cable assembly and a receiver. The portable cable assembly includes a power plug and a transmitter with a plug portion that mates with a receptacle on the receiver. A magnetic latch secures the plug portion in the ring receptacle. The transmitter includes a power supply, a power switch, a signal sensor, and a transmitting inductor. The receiver includes a receiving inductor, a signal coil, a magnet, a power converter, a temperature sensor, and an isolation switch. When the transmitter is coupled with the receiver, the power switch is operated by the magnet, the signal sensor is magnetically coupled to the signal coil, and the transmitting inductor is magnetically coupled to the receiving inductor. The normally open isolation switch is operated when the power converter is energized by the transmitter.