Secondary Winding Ferrite Layout for Flux and Thermal Balance
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Solution Overview
Problem
Existing secondary-sided arrangements of winding structures for inductive power transfer in electric vehicles experience thermal imbalance and increased losses due to uneven flux density distribution among magnetically conductive elements, leading to thermal disbalance and inefficiencies.
Innovation Solution
The proposed solution involves a secondary-sided arrangement with a winding structure comprising multiple subwindings, where lateral outer magnetically conducting elements have a larger width than inner elements, and the arrangement of these elements is optimized to minimize flux density and thermal stress, including the use of non-magnetically conducting materials and varying geometries to reduce magnetic flux leakage and enhance manufacturing simplicity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If lateral outer magnetically conducting elements have the same width as inner elements, then manufacturing is simpler, but thermal imbalance and losses increase due to uneven flux density distribution
Solution Approach 1:
The patent applies local quality by differentiating the width of magnetically conducting elements based on their position: lateral outer elements have a larger width than inner elements. This local variation compensates for the higher flux density in outer rows, achieving more uniform flux distribution across all elements and reducing thermal imbalance and energy losses.
2Reliability
If magnetically conducting elements are arranged with optimized spacing and geometry, then flux density distribution improves, but manufacturing complexity increases
Solution Approach 1:
The patent employs asymmetry by making lateral outer magnetically conducting elements wider than inner elements. This asymmetric design creates a more uniform flux density distribution across the array, preventing thermal imbalance in the ferrite structure while maintaining a relatively simple manufacturing process through standardized production of different width elements.
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 effectively minimizes thermal stress imbalance and losses by optimizing flux density distribution, allowing for efficient power transfer and reduced installation space requirements while maintaining desired magnetic properties.
Implementation Method 1
a receiving device adapted to receive an alternating electromagnetic field and to produce an alternating electric current by electromagnetic induction
Implementation Method 2
a rectifier adapted to convert an alternating current (AC) to a direct current (DC)
Implementation Method 3
The DC can be converted into an AC by means of an inverter
Implementation Method 4
The primary winding structure(s) and the secondary winding structure(s) form a high frequency transformer to transfer electric energy to the vehicle
Data Source
AI summary
A secondary-sided arrangement of at least one secondary winding structure includes at least one phase line and one secondary winding structure per phase line, wherein the secondary-sided arrangement comprises at least two magnetically conducting elements, at least one lateral outer magnetically conducting element and at least one inner magnetically conducting element, wherein a width of the at least one lateral outer magnetically conducting element is larger than a width of the at least one inner magnetically conducting element and/or a length of the at least one inner magnetically conducting element is smaller than a length of the at least one lateral outer magnetically conducting element. A method for manufacturing a secondary-sided arrangement is also disclosed.