Nanocrystalline Core Structure for Low-Loss Wireless Charging
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Solution Overview
Problem
Existing wireless charging systems experience energy loss due to eddy current losses in ferrite cores, which decrease charging efficiency, particularly at higher operating frequencies.
Innovation Solution
Utilizing nanocrystalline sheets oriented perpendicularly to the base plane to form a core structure with coil windings, which reduces eddy current losses and enhances magnetic permeability, especially in the 100-400 kHz frequency range.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If ferrite cores are used in wireless charging systems, then magnetic properties are improved, but eddy current losses increase especially at higher operating frequencies
Solution Approach 1:
The ferrite core is segmented into multiple thin sheets stacked together, with each sheet separated by insulating layers. This segmentation interrupts the eddy current paths, significantly reducing eddy current losses while maintaining the magnetic properties needed for wireless charging operation.
Solution Approach 2:
Different regions of the core structure are optimized for different functions: the nanocrystalline sheets provide high magnetic permeability in the magnetic flux paths, while the insulating layers between sheets provide electrical isolation to reduce eddy currents. This local differentiation of material properties resolves the contradiction between magnetic performance and energy loss.
2Productivity
If operating frequency is increased to improve charging speed, then productivity is improved, but eddy current losses increase
Solution Approach 1:
By segmenting the core into thin insulated sheets, the patent enables operation at higher frequencies without proportionally increasing eddy current losses. The segmented structure maintains low losses across a broader frequency range, allowing the system to operate at higher frequencies for faster charging.
Solution Approach 2:
The core uses composite construction combining nanocrystalline magnetic material with insulating layers. This composite structure provides both the magnetic properties needed for efficient power transfer and the electrical isolation needed to suppress eddy currents at high operating frequencies.
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 nanocrystalline core structure achieves negligible eddy current loss and higher magnetic permeability, improving wireless charging efficiency and compatibility with high-frequency operations.
Implementation Method 1
enhances magnetic permeability, especially in the 100-400 kHz frequency range
Implementation Method 2
reduces eddy current losses, achieving negligible eddy current loss
Implementation Method 3
One or more coils are wound around each of the one or more posts to form coil windings
Data Source
AI summary
Implementations described herein provide systems and methods for wireless charging. In one implementation, a base has a planar surface. One or more posts extend from the planar surface of the base to form a core. Each of the one or more posts is formed from a plurality of nanocrystalline sheets. The plurality of nanocrystalline sheets of each of the one or more posts is oriented in planes perpendicular to the planar surface of the base. One or more coils are wound around each of the one or more posts to form coil windings.