Wireless Charging H-Bridge Control for Wide Voltage Range

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Solution Overview

Problem

Existing wireless charging systems face challenges in efficiently transferring power to vehicles with varying battery voltages due to energy loss from frequent switching of power electronics, particularly in H bridge circuits, leading to inefficiencies and increased costs.

Innovation Solution

A switch control circuit controls H bridge circuits to toggle between specific configurations, ensuring that one half bridge remains in a constant state while the other half bridge switches, reducing voltage swings and energy loss across the resonant tank, allowing charging across a wide voltage range (200 V to 1000 V).

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If frequent switching of power electronics is performed to accommodate varying battery voltages, then adaptability to different voltage ranges is improved, but energy loss increases

Engineering Contradiction:
Improvevoltage range adaptabilityVSAvoidenergy loss
Core Design Contradiction:
Adaptability or versatilityVSLoss of energy

Solution Approach 1:

The H bridge circuit is divided into two independent half bridges, where each half bridge can be controlled separately. This segmentation allows the system to toggle between configurations with fewer switching events, reducing energy loss while maintaining voltage range adaptability.

Inventive Principle:
Principle #1Segmentation

Solution Approach 2:

The switching circuit dynamically toggles between different configurations (first and second switch configurations) based on the detected voltage conditions. This dynamic switching enables the system to adapt to varying battery voltages while minimizing the frequency of switching events to reduce energy loss.

Inventive Principle:
Principle #15Dynamics

2Adaptability or versatility

If switching circuit configurations are frequently toggled to match varying loads and voltages, then adaptability to different operating conditions is improved, but system efficiency deteriorates

Engineering Contradiction:
Improveoperating condition adaptabilityVSAvoidcharging efficiency
Core Design Contradiction:
Adaptability or versatilityVSProductivity

Solution Approach 1:

By segmenting the H bridge into two independently controllable half bridges, the system can adjust to different operating conditions through selective switching of half bridges rather than complete circuit reconfiguration, thereby maintaining adaptability while improving charging efficiency.

Inventive Principle:
Principle #1Segmentation

Solution Approach 2:

The system changes switching parameters (which half bridge to toggle, switching frequency, duty cycle) based on detected operating conditions such as battery voltage and load requirements. This parameter-based adaptation allows the system to maintain high efficiency across varying operating conditions.

Inventive Principle:
Principle #35Parameter changes

3Loss of energy

If voltage swings across the resonant tank are reduced through controlled switching, then energy loss is reduced, but the ability to transfer power across wide voltage ranges may be limited

Engineering Contradiction:
Improveenergy lossVSAvoidvoltage range capability
Core Design Contradiction:
Loss of energyVSAdaptability or versatility

Solution Approach 1:

The switching circuit dynamically adjusts its configuration based on the detected voltage conditions, allowing the system to maintain low voltage swings and energy loss while still accommodating a wide voltage range (200V to 1000V) through adaptive switching between different half bridge configurations.

Inventive Principle:
Principle #15Dynamics

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 reduces energy loss by up to 50% and stabilizes voltage swings, enabling efficient wireless charging across a broader voltage range with fewer switching events, thus enhancing charging efficiency and reducing system costs.

Implementation Method 1

Inductive charging uses electromagnetic induction to generate, or otherwise provide, electricity to devices without necessarily requiring physical electrical connectivity

Methodology Applied
Scientific EffectElectromagnetic induction: Electromagnetic Induction

Implementation Method 2

causing wireless power transfer from the first wireless charging pad to a second wireless charging pad using a voltage generated from the repeatedly toggling

Methodology Applied
Scientific EffectElectromagnetic resonance: Resonance

Data Source

PatentEP4656443A1Switch configuration control for wireless charging circuits
Publication Date: 2025.12.03 TESLA INC
  • EP4656443A1 patent drawingFigure 1A
  • EP4656443A1 patent drawingFigure 1B
  • EP4656443A1 patent drawingFigure 1C

AI summary

A method of wireless power transfer can include energizing a first wireless charging pad that includes a switching circuit, repeatedly toggling the switching circuit between a first switch configuration and a second switch configuration, and causing wireless power transfer from the first wireless charging pad to a second wireless charging pad using a voltage generated from the repeatedly toggling. During the repeatedly toggling, switches of a first half bridge of the switching circuit change a state between the first switch configuration and the second switch configuration, and switches of a second half bridge of the switching circuit remain in a same state for the first switch configuration and the second switch configuration. In certain embodiments, the first wireless charging pad can be a ground pad and the second wireless charging pad can be a vehicle pad of a vehicle. Other methods and related wireless charging pads are disclosed.