Modular Magnetic Coupling Layout for Coreless Energy Transfer

Resolve Bottlenecks,
Find Innovative Solutions
Generate Solutions

Solution Overview

Problem

Magnetic coupling devices for electrical circuits face challenges with complex maintenance and low energy transfer efficiency, particularly when no magnetic core is used.

Innovation Solution

A magnetic coupling device with coils arranged in individual modules along a closed curved line, where each coil has a winding axis extending along the bisectors of the curve, allowing for easy maintenance and efficient energy transfer without the need for a magnetic core.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If coils are arranged in a dense intimate configuration with a magnetic core, then magnetic coupling strength is improved, but maintenance complexity increases

Engineering Contradiction:
Improvemagnetic coupling strengthVSAvoidmaintenance complexity
Core Design Contradiction:
ReliabilityVSEase of repair

Solution Approach 1:

The magnetic coupling device is divided into multiple independent coil modules arranged along a closed curved line. Each coil can be accessed and maintained individually without dismantling the entire assembly, as they are distributed with spacing rather than densely packed. This segmentation resolves the contradiction by maintaining magnetic coupling effectiveness through proper geometric arrangement while enabling easy individual access for maintenance.

Inventive Principle:
Principle #1Segmentation

2Ease of repair

If coils are arranged with spacing for easy maintenance, then ease of maintenance is improved, but magnetic coupling strength decreases

Engineering Contradiction:
Improveease of maintenanceVSAvoidmagnetic coupling strength
Core Design Contradiction:
Ease of repairVSReliability

Solution Approach 1:

The coils are arranged along a closed curved line (circular or elliptical geometry) rather than a straight line. This curvature allows coils to be spaced apart for maintenance access while the closed-loop geometry ensures that magnetic field lines remain confined and effective coupling is maintained between adjacent coils. The curved arrangement optimizes both maintenance accessibility and magnetic coupling strength simultaneously.

Inventive Principle:
Principle #14Spheroidality (Curvature)

3Device complexity

If no magnetic core is used, then device complexity is reduced, but energy transfer efficiency decreases

Engineering Contradiction:
Improvedevice complexityVSAvoidenergy transfer efficiency
Core Design Contradiction:
Device complexityVSLoss of energy

Solution Approach 1:

The magnetic core is extracted/removed from the traditional transformer structure, eliminating the complexity associated with magnetic core materials, saturation issues, and core losses. The invention achieves effective magnetic coupling without a core by relying on the geometric arrangement of coils along a closed curved line, which provides sufficient magnetic coupling for the application while simplifying the device structure.

Inventive Principle:
Principle #2Taking out (Extraction)

4Object-generated harmful factors

If coils are arranged in a closed curved line configuration, then magnetic field confinement is improved, but manufacturing complexity increases

Engineering Contradiction:
Improvefield leakageVSAvoidmanufacturing complexity
Core Design Contradiction:
Object-generated harmful factorsVSEase of manufacture

Solution Approach 1:

The closed curved line arrangement (circular or elliptical) of coils provides natural magnetic field confinement within the loop geometry. The curved configuration guides magnetic field lines along the closed path, minimizing leakage outside the structure. While the geometry is curved, the manufacturing complexity is managed by using standard coil winding techniques on a curved form, making the solution practical despite the non-linear arrangement.

Inventive Principle:
Principle #14Spheroidality (Curvature)

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 easy access and maintenance of coils while ensuring effective magnetic coupling and high energy transfer efficiency, even at high power and frequency, with galvanic isolation for secure and efficient energy transmission.

Implementation Method 1

magnetic coupling device for connecting a first and a second circuit, the magnetic coupling device comprising: a first set of first coils intended to be connected to the first circuit, a second set of second coils intended to be connected to the second circuit

Methodology Applied
Scientific EffectElectromagnetic induction: Electromagnetic Induction

Data Source

PatentEP4266332A1Magnetic coupling device and method for manufacturing such a magnetic coupling device
Publication Date: 2023.10.25 EFFITECH (PVT) LTD
  • EP4266332A1 patent drawingFigure 1~2
  • EP4266332A1 patent drawingFigure 3~4
  • EP4266332A1 patent drawingFigure 5a~5d

AI summary

The invention relates to a magnetic coupling device (1) for connecting a first and a second circuit (2, 3). The magnetic coupling device (1) comprises: a first and a second set (10, 20) of first and second coils (12a, 12b, 12c, 22a, 22b, 22c...) respectively. Each first and second coil (12a, 12b, 12c, 22a, 22b, 22c...) is provided as an individual module (11a, 11b, 11c, 22a, 22b, 22c...). The first and second coils (12a, 12b, 12c...,22a, 22b, 22c...) are distributed along a closed curved line (30) with their winding axes extending along bisectors of said closed curved line (30), two successive first coils (12a, 12b, 12c...) along the closed curved line (30) being separated from each other by at least one second coil (22a, 22b, 22c...).