Layered Double-D Coil Layout for Efficient Low-Leakage Power Transfer
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Solution Overview
Problem
Conventional inductive wireless power transfer systems face challenges in maximizing power transfer efficiency and minimizing magnetic flux leakage, which limits their adoption in new technologies and poses health hazards.
Innovation Solution
A wireless power transfer device with stacked coil layers, where each coil layer has windings connected in series and oriented in the same rotational direction, enhancing constructive magnetic field interference and mutual inductance to increase power transmission efficiency and range while minimizing lateral space.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If conventional inductive wireless power transfer systems are used, then power transfer is achieved, but efficiency is low and magnetic flux leakage is high
Solution Approach 1:
The coil structure is segmented into multiple layers (first coil layer, second coil layer, etc.) with each layer containing series-connected windings. This segmentation allows optimization of magnetic field distribution across layers, improving power transfer efficiency while containing magnetic flux within the layered structure, thereby reducing leakage.
Solution Approach 2:
The patent transitions from conventional single-layer or planar coil configurations to a three-dimensional layered structure. By stacking multiple coil layers vertically and connecting them in series, the system achieves superior magnetic coupling and flux containment in the vertical dimension, improving efficiency and reducing lateral magnetic flux leakage.
2Area of stationary object
If power transmission range is increased, then application area expands, but magnetic flux leakage into surrounding environment increases
Solution Approach 1:
The multi-layered coil structure segments the magnetic field generation across multiple levels, allowing the system to extend power transmission range vertically and laterally while maintaining flux containment within each layer's optimized geometry, preventing excessive leakage into the surrounding environment.
Solution Approach 2:
Each coil layer is designed with specific winding configurations and orientations optimized for its local position in the stack. This local optimization ensures that magnetic flux is directed efficiently toward the target area while being contained within the layered structure, enabling extended range without proportional increase in leakage.
3Loss of energy
If coil layers are stacked to enhance power transmission, then efficiency improves, but device complexity increases
Solution Approach 1:
Multiple coil layers are merged into a single integrated wireless power transfer device, with series connections between layers that simplify the electrical architecture. This merging approach achieves enhanced efficiency through improved magnetic coupling while avoiding the complexity of multiple independent systems, as the layers function as a unified structure.
Solution Approach 2:
The layered coil structure serves multiple functions simultaneously: it enhances power transfer efficiency through improved magnetic coupling, contains magnetic flux to reduce leakage, and maintains a compact form factor. This multi-functionality within a single structural design reduces overall system complexity compared to using separate components for each function.
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 LDD coil configuration achieves higher inductance values and power transfer efficiency, reducing magnetic flux leakage and maintaining a compact footprint, suitable for diverse applications including electric vehicles and biomedical implants.
Implementation Method 1
With inductive wireless power transfer, power is transferred between wire coil structures by a magnetic field
Implementation Method 2
power is transferred between wire coil structures by a magnetic field
Data Source
AI summary
A wireless power transfer device is disclosed that includes at least a first coil layer and a second coil layer, each coil layer including two coil windings positioned adjacent to one another in a lateral direction; wherein the two coil windings in each corresponding coil layer are connected in series and are wound in the same rotational direction, and the first and second coil layers are stacked in layers on top of one another. The magnetic fields of the coil layers can interact with one another in a constructive manner such that the overall efficiency and power transmission of the wireless power transfer device can be enhanced.