Wireless Power Transfer Coil Structure for Efficient EV Charging
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Solution Overview
Problem
Current wireless power transfer systems for electric vehicles face inefficiencies due to the design of transmission and reception pads, particularly in the structure of coils and ferrite materials, which affect power transfer efficiency and require improvements to enhance performance.
Innovation Solution
The implementation of a novel coil structure with a primary and secondary coil configuration, where the coils are wound with flat wire and have rounded corners, and a ferrite member is strategically positioned to optimize magnetic coupling, along with a power transfer circuit to enhance efficiency and reduce cooling costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If conventional coil structures with square wires are used, then manufacturing is simpler, but power transfer efficiency is lower
Solution Approach 1:
The patent applies curvature by rounding the corners of the flat wire cross-section. This curved geometry at the corners improves the magnetic field distribution and reduces eddy current losses, thereby increasing power transfer efficiency while maintaining the flat wire's manufacturing advantages
2Loss of energy
If ferrite structures are densely arranged to improve magnetic coupling, then power transfer efficiency increases, but heat dissipation becomes more difficult
Solution Approach 1:
The patent applies local quality by strategically positioning ferrite members at specific locations where magnetic coupling is most needed, rather than uniformly distributing them. This localized arrangement optimizes power transfer efficiency while leaving spaces for heat dissipation pathways
Solution Approach 2:
The patent introduces air gaps or cooling channels as intermediary spaces between ferrite structures. These intermediaries facilitate heat dissipation while the ferrite members maintain adequate spacing to allow thermal management without compromising magnetic coupling efficiency
3Reliability
If flat wire with rounded corners is used, then electromagnetic characteristics are improved, but manufacturing precision requirements increase
Solution Approach 1:
The patent applies parameter changes by optimizing the corner rounding radius to a specific range that balances electromagnetic performance improvement with manufacturing feasibility. This parameter optimization ensures that the rounded corners provide sufficient electromagnetic benefit without requiring excessive manufacturing precision
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 configuration increases power transfer efficiency, allows for easier cooling, and provides greater flexibility in arranging ferrite pads, resulting in improved electromagnetic characteristics and reduced maintenance costs.
Implementation Method 1
a ferrite member configured to form a magnetic coupling with the primary coil
Data Source
AI summary
Disclosed is a wireless power transmission pad prepared to transmit wireless power to a reception pad including a secondary coil. The wireless power transmission pad includes: a primary coil arranged to surround a central space; a ferrite forming a magnetic coupling with the primary coil; and a housing supporting the primary coil and the ferrite. The primary coil of the wireless power transmission pad is formed in a state in which a flat wire or a planar wire is wound at least once.