Cross-Layer Multilayer Magnetic Sheet for Flux Leakage Control
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Solution Overview
Problem
Existing magnetic sheets for contactless charging in electric vehicles are insufficient in size and prone to magnetic flux leakage due to the narrow width of alloy ribbons, and the process of stacking single-layer ribbons is labor-intensive.
Innovation Solution
A multilayer magnetic sheet design with alternating laminate substrate layers, where the long sides of adjacent laminate substrates in different layers intersect, reducing continuous magnetic gaps and minimizing the number of man-hours required for assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If alloy ribbons are stacked one by one to form a magnetic sheet, then the magnetic sheet can be manufactured, but the number of man-hours becomes large
Solution Approach 1:
The patent combines multiple alloy ribbons into a single laminate substrate before stacking. Specifically, multiple alloy ribbons are bonded together to form one integrated laminate substrate, which then serves as a single unit in the stacking process. This merging approach reduces the number of individual stacking operations required, thereby decreasing the number of man-hours while maintaining the magnetic sheet's functionality.
Solution Approach 2:
The patent performs preliminary assembly of multiple alloy ribbons into a laminate substrate before the final stacking stage. By pre-assembling the ribbons into a unified structure, the subsequent stacking process becomes more efficient. This preliminary action prepares the components in advance, reducing the complexity and time required during the final assembly of the magnetic sheet.
2Area of stationary object
If single-layer alloy ribbons are used to widen the surface, then the width can be increased, but the number of stacking operations increases significantly
Solution Approach 1:
The patent merges multiple alloy ribbons into a single laminate substrate that provides the required surface width. Instead of stacking individual narrow ribbons one by one to achieve the desired width, the ribbons are combined in advance to form a wider integrated substrate. This approach achieves the necessary surface area while maintaining efficient assembly processes.
3Ease of manufacture
If alloy ribbons are made narrower to fit existing designs, then the magnetic sheet can be manufactured with current processes, but the magnetic flux leakage increases
Solution Approach 1:
The patent transitions from using narrow single-layer ribbons to wider multi-layer laminate substrates. By changing the dimensional structure from narrow and thin to wide and layered, the magnetic sheet can contain magnetic flux more effectively while still being manufacturable. The increased width and multi-layer construction provide better magnetic flux containment without requiring changes to existing manufacturing processes.
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 design enhances magnetic characteristics by preventing continuous magnetic gaps and reduces manufacturing time, making it suitable for high-power contactless charging applications like electric vehicles.
Implementation Method 1
a magnetic flux generated in a primary transmission coil of a power feeding device generates an electromotive force in a secondary transmission coil of a power receiving device
Implementation Method 2
The magnetic sheet arranged in this manner has a role as a magnetic shielding material for preventing leakage of a magnetic flux during charging
Implementation Method 3
a role as a yoke member for refluxing a magnetic flux generated in a coil during charging
Data Source
AI summary
A multilayer magnetic sheet comprises a first laminate substrate layer and a second laminate substrate layer, which are stacked in a thickness direction and in each of which laminate substrates each formed in a band shape are arranged in a plate shape such that long sides of the laminate substrates are adjacent to each other, the laminate substrate comprising two or more stacked layers of magnetic ribbons. A direction in which the long sides of the laminate substrates in the second laminate substrate layer extend intersects a direction in which the long sides of the laminate substrates in the first laminate substrate layer extend.