Overlapping Magnetic Cores for Wireless Power Transfer
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Solution Overview
Problem
Current wireless power transfer systems face inefficiencies in transferring power over distances due to limited magnetic flux coupling, particularly in designs that rely on traditional coil configurations and materials.
Innovation Solution
The use of overlapping magnetic cores with recessed primary coils and protruding secondary coils, where the secondary coil is inserted into the recess of the primary coil, enhancing magnetic flux coupling and efficiency by maintaining an air gap or using high permeability enclosures for separation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If traditional coil configurations are used for wireless power transfer, then the system structure is simple, but the magnetic flux coupling is limited and transfer efficiency is reduced
Solution Approach 1:
The patent implements nesting by placing the secondary magnetic core inside the recess of the primary magnetic core, with the secondary coil wound around the protruding center portion that inserts into the primary coil's recess. This nested configuration maximizes magnetic flux coupling between the two coils while maintaining a compact structure, achieving greater than 95% power transfer efficiency over distances of 1 mm to 5 mm.
Solution Approach 2:
The patent transitions from traditional planar coil arrangements to a three-dimensional overlapping configuration. The primary magnetic core provides a recess with side walls and a base, while the secondary magnetic core includes a protruding center portion that inserts into this recess. This vertical stacking and overlapping arrangement in the third dimension significantly enhances magnetic flux coupling compared to conventional side-by-side or stacked planar configurations.
2Loss of energy
If magnetic cores are placed close together to improve coupling, then power transfer efficiency increases, but magnetic interference and saturation occur
Solution Approach 1:
The patent introduces an air gap as an intermediary element between the primary and secondary magnetic cores. The recess structure of the primary magnetic core and the protruding center portion of the secondary magnetic core create a controlled air gap that maintains close proximity for strong magnetic coupling while preventing direct contact that would cause magnetic saturation and interference. This air gap mediator allows the system to achieve greater than 95% efficiency without the harmful effects of magnetic saturation.
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 achieves greater than 95% efficiency in wireless power transfer over distances of 1 mm to 5 mm, enabling effective power transfer to multiple receivers and supporting high voltage outputs.
Implementation Method 1
The protruding center portion overlaps the primary magnetic core side wall and is configured to provide separation between the primary magnetic core and the secondary magnetic core
Data Source
AI summary
A primary coil can be inside the recess, where the primary coil is wound around the center of the recess. A secondary magnetic core can include a protruding center portion that is configured for insertion into the center of the recess so that the protruding center portion overlaps the primary magnetic core side wall and is configured to provide separation between the primary magnetic core and the secondary magnetic core. A secondary coil can be wound around the protruding center portion of the secondary magnetic core.