Polygonal EV Charging Coils With Honeycomb Shielding
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Solution Overview
Problem
Existing inductive charging systems for electric vehicles are heavy, complex, and inefficient, with issues such as electromagnetic interference, eddy current losses, and low efficiency, and require large coils.
Innovation Solution
A lightweight, compact inductive charging system using ferrite bars and a honeycomb metal shielding layer with matching polygonal coils to reduce proximity effect and enhance coupling, forming an essentially closed system with low electrical resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If traditional inductive charging coils are used, then power transfer is achieved, but the system becomes heavy and complex with large coil sizes
Solution Approach 1:
The patent divides the traditional single large coil into multiple smaller hexagonal coils arranged in a mosaic pattern. This segmentation allows the system to achieve the required magnetic field coverage while using smaller, lighter individual coil elements, directly reducing overall weight and complexity.
Solution Approach 2:
The patent employs a composite structure combining copper coils with ferrite bars and honeycomb aluminum shielding. This composite material approach optimizes magnetic field generation while reducing weight compared to traditional solid metal constructions, addressing the weight versus size contradiction.
2Object-affected harmful factors
If continuous metal shielding is used to block electromagnetic interference, then electromagnetic interference is reduced, but eddy current losses and heating occur in the shielding material
Solution Approach 1:
The patent replaces continuous metal shielding with a honeycomb structure consisting of segmented hexagonal cells. This segmentation interrupts the eddy current paths while maintaining electromagnetic interference blocking capability, as the discontinuous structure prevents large-scale current loops from forming in the shielding material.
Solution Approach 2:
The honeycomb aluminum shielding is a porous-like structure with hexagonal voids that allows it to block electromagnetic interference while minimizing eddy current losses. The porous/honeycomb structure provides sufficient shielding effectiveness without the continuous metal pathways that cause excessive heating.
3Power
If large receiver coils are used for vehicle charging, then sufficient power transfer is achieved, but the system complexity and size increase
Solution Approach 1:
The patent implements segmentation by using multiple smaller hexagonal coils in a mosaic arrangement instead of a single large coil. This approach achieves the required power transfer capability through collective action of multiple units while simplifying individual component design and reducing overall system complexity.
Solution Approach 2:
The hexagonal coil module serves multiple functions: it generates magnetic field for power transfer, provides structural framework, and works with ferrite bars for field concentration. This multi-functionality reduces the need for separate components, thereby reducing system complexity while maintaining power transfer capability.
4Ease of manufacture
If traditional coil shapes are used, then manufacturing is simple, but proximity effect reduces coupling efficiency between transmitter and receiver coils
Solution Approach 1:
The patent adopts hexagonal geometry instead of traditional circular or rectangular shapes. The hexagonal shape provides asymmetric characteristics that optimize magnetic field distribution and coupling between transmitter and receiver coils, reducing proximity effect while remaining manufacturable through standard fabrication processes.
Solution Approach 2:
The hexagonal shape with its curved edges and uniform distribution of vertices around the center optimizes magnetic flux patterns and coupling coefficients. This geometric curvature approach improves field uniformity and coupling efficiency compared to sharp-cornered rectangular designs, while maintaining ease of manufacture.
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 system minimizes electromagnetic interference, reduces power consumption, and enhances charging efficiency while allowing retrofitting to electric vehicles.
Implementation Method 1
Power is transferred using a non-contact magnetic induction
Implementation Method 2
Both the receiver module and the transmitter module of the inductive charging system include ferrite bars
Implementation Method 3
an apertured metal shielding layer... a honeycomb shielding layer
Data Source
AI summary
An inductive charging system for charging an electric vehicle, the inductive charging system comprising: an onboard vehicle assembly, which includes a receiver module comprising a receiver coil that defines a central aperture, an apertured metal shielding layer and a series of ferrite bars between the receiver coil and the apertured metal shielding layer, the series of ferrite bars radiating outward from the central aperture; and a charging station assembly, which includes a transmitter module comprising a transmitter coil that defines a central aperture, an apertured metal shielding layer and a series of ferrite bars between the transmitter coil and the apertured metal shielding layer, the series of ferrite bars radiating outward from the central aperture, wherein the receiver coil and the transmitter coil are a matching geometry of polygons having four to ten sides with central apertures that are a matching geometry to the matching geometry of polygons.