Reception Unit Flux Guide Casting for Contactless Power
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Solution Overview
Problem
The brittleness and poor processability of flux-conducting elements made from materials like ferrite, which are used to concentrate magnetic flux in receiving units for contactless power transmission, lead to labor-intensive manufacturing and assembly challenges.
Innovation Solution
A receiving unit design featuring a basic body with depressions for prefabricated flux-conducting elements formed from a contiguous shaped part, integrated with a receiver coil, using a liquid mixture of casting resin and high-permeability powder to create a complete assembly unit, simplifying the manufacturing process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If flux-conducting elements are made from ferrite or similar materials by pressing and sintering, then they achieve high permeability to concentrate magnetic flux, but they become brittle and mechanically delicate
Solution Approach 1:
The patent uses composite materials by combining ferrite powder with a binding agent to form a flexible flux-conducting element. This composite approach maintains the high permeability of ferrite while the binding agent provides mechanical strength and flexibility, resolving the contradiction between magnetic performance and mechanical durability.
Solution Approach 2:
The patent changes the physical state and processing parameters of the flux-conducting material. Instead of sintering ferrite into rigid structures, the invention uses ferrite powder mixed with binding agents that can be formed into flexible shapes, fundamentally changing the material's mechanical properties while preserving its magnetic functionality.
2Reliability
If flux-conducting elements are made from brittle materials like ferrite, then they can concentrate magnetic flux effectively, but they are poorly processable and require labor-intensive assembly
Solution Approach 1:
By creating a composite material of ferrite powder and binding agent, the invention achieves both magnetic functionality and ease of processing. The mixture can be easily formed into desired shapes and integrated with the receiver coil, eliminating the need for complex assembly of separate brittle components.
Solution Approach 2:
The patent merges the flux-conducting elements with the receiver coil assembly into a single integrated structure. The flexible flux-conducting material can be directly applied to or integrated with the coil, combining multiple components into one manufacturable unit and greatly simplifying the manufacturing process.
3Shape
If individual flux-conducting elements are connected into a grid frame by bonding, then they form a complete structure, but the joining process becomes very labor-intensive
Solution Approach 1:
The invention merges the formation of flux-conducting elements and their arrangement into a single forming process. The flexible composite material can be molded directly into the final grid frame shape, eliminating the need for separate bonding operations to assemble individual elements.
Solution Approach 2:
The flux-conducting material is prepared in advance as a pre-formed composite that already has the desired grid frame structure. This preliminary formation eliminates the need for subsequent assembly operations, as the element arrives at the assembly stage already configured in its final shape.
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 approach eliminates the difficulties associated with brittle flux-conducting elements by forming a contiguous grid frame that can be prefabricated as a complete assembly unit, reducing labor intensity and improving mechanical stability.
Implementation Method 1
flux-conducting elements, which are intended to concentrate lines of flux and which consist of a material with high permeability compared to that of air
Implementation Method 2
A liquid mixture is prepared from a casting resin and a powder of a material with high permeability, and the liquid mixture is then poured into the depressions to form the flux-conducting elements
Data Source
AI summary
A reception unit is provided including a receiver coil for the contactless transfer of electric energy. The receiver coil includes a plurality of flux guiding elements (16a, 16b) that are made of a highly permeable material and that are designed to concentrate the field lines. The flux guiding elements (16a, 16b) form a continuous molded part that is embodied in a base body (18) and that is combined with the base body to form a component that can be completely prefabricated. The molded part is produced by casting and the base body (18) is used as a casting mold.