Wireless Charging Magnetic Body Layout for Flux Offset and Heat Reduction
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Solution Overview
Problem
Current wireless charging devices for electric vehicle batteries face issues with low charging efficiency and increased heat generation due to the use of Mn—Zn ferrite materials, which are brittle and have high internal AC resistance and low magnetic permeability, leading to magnetic flux linkage and heat issues in the control circuit.
Innovation Solution
A wireless charging device is designed with a first magnetic body made of soft magnetic materials and a second magnetic body, a hard magnetic material permanent magnet, strategically positioned to offset magnetic flux linkage, improving charging efficiency and reducing heat generation by using a planar shape and aluminum shield.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If Mn—Zn ferrite sintered material is used for the magnetic body, then high magnetic permeability is achieved, but the material becomes brittle and easily damaged
Solution Approach 1:
The magnetic body is divided into two distinct parts: a first magnetic body part made of Mn-Zn ferrite sintered material for high magnetic permeability, and a second magnetic body part made of composite magnetic powder material for durability. This segmentation allows each part to fulfill its specific function without compromising the other.
Solution Approach 2:
The second magnetic body part uses a composite material consisting of magnetic powder (such as ferrite, iron powder, or alloy powder) combined with a binder material. This composite structure provides both the required magnetic properties and improved mechanical durability compared to traditional sintered materials.
2Strength
If composite magnetic powder material is used instead of Mn—Zn ferrite, then durability is improved, but internal AC resistance increases and magnetic permeability decreases
Solution Approach 1:
The magnetic body is divided into two distinct parts: a first magnetic body part made of Mn-Zn ferrite sintered material for high magnetic permeability, and a second magnetic body part made of composite magnetic powder material for durability. This segmentation allows each part to fulfill its specific function without compromising the other.
3Ease of manufacture
If low magnetic permeability material is used, then manufacturing is easier, but magnetic flux linkage occurs in the shield resulting in heat generation
Solution Approach 1:
The magnetic body is divided into two distinct parts: a first magnetic body part made of Mn-Zn ferrite sintered material for high magnetic permeability, and a second magnetic body part made of composite magnetic powder material for durability. This segmentation allows each part to fulfill its specific function without compromising the other.
Solution Approach 2:
The second magnetic body part acts as an intermediary between the first magnetic body part and the aluminum shield. It provides a transition zone that manages magnetic flux distribution, preventing direct flux linkage in the shield that would cause heat generation, while still allowing the use of easier-to-manufacture composite materials.
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 enhances charging efficiency and reduces heat generation by effectively managing magnetic flux linkage, improving performance and durability while minimizing material costs.
Implementation Method 1
The coil part serves to convert electrical energy into magnetic energy (magnetic field)
Implementation Method 2
a receiving unit thereof converts a strong magnetic field generated in a transmitting unit into electricity in accordance with the change in the magnetic field
Implementation Method 3
the magnetic body serves to strengthen and to shield the generated magnetic field such that the generated magnetic field has directionality
Data Source
AI summary
A wireless charging device is proposed. The wireless charging device may maximize charging efficiency improvement and heat generation reduction effect by appropriately arranging a second magnetic body on a first magnetic body, resulting in an offset of a magnetic flux linkage occurring inside an aluminum shield due to a magnetic field having passed through the first magnetic body.