Twisted Wire Sub-Coil Arrangement for Wireless Power Transfer
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Solution Overview
Problem
The complexity in manufacturing and assembly of wireless power transfer systems for vehicles increases with the need for higher power transfer, particularly due to the use of multifilar coils, which require efficient use of space and precise positioning of sub coils.
Innovation Solution
The design incorporates twisted conductor wires for sub coils that can be arranged in separate layers, allowing for increased windings and power transfer while simplifying the production process by using holders to keep each sub coil in position during assembly, and the use of a circuit card for terminating conductor wires at favorable positions to minimize extensions and enhance magnetic performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If multifilar coils with multiple sub coils are used to increase power transfer capability, then the power transfer capacity is improved, but the manufacturing and assembly complexity increases significantly
Solution Approach 1:
The coil system is divided into multiple independent sub-coils (first sub-coil, second sub-coil, etc.) that can be manufactured separately and then assembled together. Each sub-coil is formed by individual conductor wires that are twisted and positioned independently, allowing modular production and simplifying the overall manufacturing process while achieving high power transfer capability through parallel arrangement.
Solution Approach 2:
The sub-coils are arranged in different spatial layers and positions (first loop, second loop, central portion, outer portions) to create a three-dimensional coil structure. This spatial arrangement allows multiple conductor wires to be positioned without interfering with each other, enabling high power transfer while maintaining manageable complexity through structured spatial organization.
2Power
If the number of conductor wire windings is increased to transfer more power, then the power transfer efficiency is improved, but the space requirements and positioning precision needs increase
Solution Approach 1:
Holders are provided to accommodate and hold the sub-coils in predetermined positions before final assembly. The holders pre-position the first sub-coil, second sub-coil, and other components, ensuring correct alignment and spacing is achieved before the components are permanently fixed together. This preliminary positioning reduces the precision requirements during final assembly.
Solution Approach 2:
The holders act as intermediary components between the sub-coils and the final assembled structure. They provide a standardized interface and positioning mechanism that simplifies the alignment process, allowing sub-coils to be accurately positioned without requiring direct precision alignment between each component pair.
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 design enables more efficient use of space, allows for higher power transfer, and simplifies the assembly of wireless power transfer systems by facilitating the separate winding and positioning of sub coils, while reducing the complexity and size of the device.
Implementation Method 1
Electric vehicles and plug in hybrid vehicles can be charged wirelessly through induction coils
Data Source
AI summary
The invention relates to a device for a wireless power transfer system for a vehicle. The device comprises a coil formed by at least a first conductor wire forming a first sub coil with a plurality of windings and a second conductor wire forming a second sub coil with a plurality of windings. The coil has a first loop and a second loop positioned next to each other. The first and second loop have a central portion of the coil in common where said at least first and second conductor wires extend from the first loop to the second loop and vice versa. The first and second conductor wires are arranged next to each other in the central portion. The first and second conductor wires are arranged above each other in an outer portion of the first loop and in an outer portion of the second loop.