Sealed Litz-Wire Charging Coil Structure for Outdoor EV Use

The patent applies parameter changes by modifying the cross-sectional shape of the litz wire from circular to rectangular through pressure application during winding. This transformation increases the space factor of the coil while maintaining the litz wire structure that reduces eddy current loss, thereby resolving the contradiction between energy loss reduction and space utilization.

The patent uses a flexible resin covering member that completely covers the coil unit, providing waterproof protection and vibration resistance while maintaining adaptability for outdoor use. This flexible shell approach resolves the contradiction between adaptability and reliability by providing environmental protection without compromising the functional versatility of the charging system.

The patent employs composite materials by constructing the coil from multiple thin enameled wires twisted together to form a litz wire with rectangular cross-section. This composite structure increases the space factor while the multiple isolated conductors within the litz wire reduce eddy current loss, effectively resolving the contradiction between space utilization and energy efficiency.

The patent applies preliminary action by pre-forming the litz wire with a rectangular cross-section through pressure application before the winding process. This preliminary shaping eliminates the need for complex post-winding forming operations, thereby increasing the space factor while keeping the manufacturing process relatively simple and suitable for mass production.