Ferrite Strip Gaps and Ribs for WEVC Pad Flux Balance
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Solution Overview
Problem
Current wireless power transfer systems for electric vehicle charging face inefficiencies due to uncontrolled magnetic flux, leading to hot spots and damage from high-flux density areas, and structural vulnerabilities from brittle ferrite materials.
Innovation Solution
Incorporating intentional gaps and ribs in the ferrite strips of the power-transfer structure to balance magnetic flux density and enhance structural rigidity, reducing heat generation and material damage while maintaining efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If ferrite strips are used in wireless power transfer systems, then power transfer efficiency is improved, but high-flux density areas cause heat generation and material damage
Solution Approach 1:
The patent applies local quality by introducing intentional gaps at specific locations within the ferrite strips where high-flux density occurs. These gaps are strategically positioned to redistribute magnetic flux only in the problematic high-flux areas, while leaving other regions unaffected. This localized modification reduces heat generation in critical zones without compromising the overall power transfer efficiency of the ferrite strip structure.
Solution Approach 2:
The patent segments the continuous ferrite strip structure by introducing intentional gaps, dividing it into multiple sections. This segmentation allows the magnetic flux to be redistributed across the gaps, preventing concentration in single high-flux density areas. The segmented structure maintains the beneficial properties of ferrite for power transfer while creating flux pathways that reduce localized heating.
2Loss of energy
If ferrite strips are used for power transfer, then wireless charging efficiency is improved, but the brittle nature of ferrite causes structural vulnerabilities
Solution Approach 1:
The patent segments the brittle ferrite material into strips with intentional gaps, which prevents crack propagation throughout the entire structure. If a crack initiates in one segment, the gaps and strip structure contain it, preventing catastrophic failure of the entire ferrite component. This segmentation maintains structural reliability while preserving the power transfer efficiency of the ferrite material.
Solution Approach 2:
The patent incorporates ribs and spacing structures beforehand to provide mechanical support and cushioning to the brittle ferrite strips. These structural elements are positioned in advance to prevent bending and stress concentration that could lead to cracks. The ribs act as reinforcement that compensates for the inherent brittleness of ferrite, ensuring structural robustness before operational stresses are applied.
3Loss of energy
If ferrite strips are placed close together, then power transfer efficiency is maintained, but structural rigidity is reduced
Solution Approach 1:
The patent introduces ribs that extend in a third dimension (vertically) between the ferrite strips and the backplate. This dimensional addition provides structural rigidity without increasing the horizontal spacing between strips. The ribs create a three-dimensional reinforcement structure that mechanically supports the ferrite strips, maintaining their close proximity for efficient power transfer while compensating for reduced structural rigidity through vertical support elements.
Solution Approach 2:
The patent creates a composite structure combining ferrite strips, non-magnetic spacing material, and ribs. This composite construction integrates materials with different properties: the ferrite provides magnetic flux guidance for power transfer, the spacing material provides mechanical separation and support, and the ribs provide additional structural reinforcement. The composite structure achieves both close strip spacing for efficiency and enhanced rigidity for structural stability.
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
The solution effectively reduces power loss by 12% and heat generation, enhances structural robustness, and minimizes the risk of damage to neighboring materials, improving the overall efficiency and reliability of wireless electric vehicle charging systems.
Implementation Method 1
balance magnetic flux density in ferrite strips in a power-transfer structure
Implementation Method 2
reduce heat produced in high-flux areas of the ferrite strips
Implementation Method 3
ribs are disposed between the strips and connected to a backplate to provide structural rigidity and robustness to the pad
Data Source
AI summary
Systems and methods are described that increase pad efficiency and robustness. These systems and methods balance magnetic flux density in ferrite strips in a WEVC pad to reduce heat produced in high-flux areas of the ferrite strips. Aspects include controlled spacing between ferrite strips of a WEVC pad and intentional gaps located within high-flux areas in the strips. The sizes of the intentional gaps are determined in relation to the size of the spacing between the strips. In addition, ribs are disposed between the strips and connected to a backplate to provide structural rigidity and robustness to the pad.