Stitched Induction Coil for Wireless EV Charging
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Solution Overview
Problem
Conventional induction coils for wireless charging of electric vehicles are complex and costly, leading to high installation weight that reduces the efficiency and range of plug-in hybrid vehicles.
Innovation Solution
The method involves stitching coil wires to a carrier cross-laid structure, allowing for a flexible and cost-effective production of induction coils with reduced weight, enabling optimized coil geometry for improved energy transmission and reduced installation height.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional complex induction coils are used for wireless charging, then reliable energy transmission is achieved, but installation weight increases and manufacturing cost rises
Solution Approach 1:
The coil winding is segmented into discrete conductor loops that are individually stitched to the carrier structure. This segmentation allows for optimized material usage and reduced weight while maintaining the overall functionality of the induction coil for reliable energy transmission.
Solution Approach 2:
The induction coil combines conductor material with a carrier cross-laid structure, creating a composite assembly. This composite approach reduces the overall weight compared to conventional solid construction while maintaining structural integrity and electromagnetic functionality.
2Reliability
If conventional complex induction coils are used for wireless charging, then reliable energy transmission is achieved, but manufacturing cost increases
Solution Approach 1:
The coil is constructed from discrete conductor loops that can be individually manufactured and then stitched together. This modular approach simplifies manufacturing processes and reduces overall production costs while maintaining reliable energy transmission through the assembled structure.
Solution Approach 2:
The patent introduces a carrier cross-laid structure as an intermediary element that holds the conductor loops. This intermediary component simplifies the manufacturing process by providing a framework for assembling the coil, reducing both complexity and cost.
3Weight of moving object
If coil wires are stitched to carrier cross-laid structure, then installation weight is reduced and manufacturing cost decreases, but manufacturing precision requirements increase
Solution Approach 1:
The carrier cross-laid structure acts as a flexible yet stable framework that accommodates the conductor loops. This structure provides natural alignment features that reduce the precision requirements for stitching while maintaining the weight reduction benefits.
Solution Approach 2:
The stitching process itself creates structural reinforcement at each stitch point, meaning the act of stitching contributes to the overall structural integrity. This self-reinforcing characteristic reduces the need for excessively high precision, as the stitching serves both attachment and structural functions.
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 results in a more efficient and cost-effective induction coil design that enhances the charging efficiency and reduces the installation weight, thereby improving the overall efficiency and range of electric vehicles.
Implementation Method 1
The electrical energy from the electrical grid is transmittable in a non-contacting and wireless manner by way of an alternating magnetic field from the primary coil to the secondary coil that is coupled to the energy accumulator
Data Source
AI summary
A method is provided for producing an induction coil, in particular for a charging device for the cableless charging of an electrical energy storage device of an electrically driven motor vehicle. At least one coil wire is placed on a carrier fabric in a conductor loop-type coil pattern. The coil wire is stitched to the carrier fabric via at least one stitching wire.