Wireless Power Transfer Coil Segmentation
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Solution Overview
Problem
The complex manufacturing process of bifilar coils for wireless power transfer systems, which involves winding two conductor wires simultaneously, increases assembly time and complexity, especially for compact designs with desired electromagnetic properties.
Innovation Solution
The use of separate holders for each sub-coil allows them to be wound and positioned independently, reducing assembly time and complexity, and enabling the formation of compact coils with twisted conductor wires that would be difficult to wind simultaneously.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If two conductor wires are wound simultaneously to form a bifilar coil, then the electromagnetic properties and compactness are improved, but the assembly time and manufacturing complexity increase
Solution Approach 1:
The bifilar coil is divided into two separate sub-coils, each wound on its own holder. This segmentation allows each sub-coil to be manufactured independently with simpler processes, while the holders maintain precise positioning when assembled together, resolving the contradiction between manufacturing simplicity and positioning precision.
Solution Approach 2:
The holders are prepared in advance with positioning features and connection structures before the sub-coils are wound. This preliminary preparation of the holders enables the sub-coils to be assembled precisely without requiring complex simultaneous winding operations, reducing manufacturing complexity while maintaining precision.
2Reliability
If two conductor wires are wound simultaneously to form a bifilar coil, then the electromagnetic properties are improved, but the assembly time increases
Solution Approach 1:
By segmenting the bifilar coil into two separately wound sub-coils on individual holders, each sub-coil can be manufactured independently and in parallel. This maintains the electromagnetic performance through proper positioning while significantly increasing assembly productivity through parallel manufacturing processes.
Solution Approach 2:
The holders are designed with self-aligning features and integrated connection structures that automatically position the sub-coils correctly during assembly. This self-service mechanism eliminates the need for complex alignment procedures, maintaining electromagnetic performance while reducing assembly time.
3Productivity
If separate holders are used for each sub-coil, then the assembly time is reduced, but the device complexity increases
Solution Approach 1:
The two holders are designed to be connected together to form an integrated structure that supports both sub-coils. This merging of holders into a unified assembly reduces the overall device complexity compared to having completely separate components, while still allowing parallel manufacturing and quick assembly.
Solution Approach 2:
The holders are designed with multi-functional features including positioning, support, and electrical connection capabilities. This universality reduces the need for additional separate components, simplifying the overall device structure while maintaining high assembly productivity through the separate holder design.
4Ease of manufacture
If separate holders are used for each sub-coil, then the assembly process is simplified, but the compactness of the device may be affected
Solution Approach 1:
The two holders are designed to nest together or interlock in a compact arrangement, with one holder partially contained within or adjacent to the other. This nesting configuration maintains the manufacturing simplicity of separate holders while minimizing the overall device volume through space-efficient packaging.
Solution Approach 2:
The holders and sub-coils are arranged in a three-dimensional configuration rather than a simple planar layout. This dimensional arrangement allows the separate holders to be positioned in space-efficient orientations, maintaining ease of manufacture while achieving compact device volume through vertical or diagonal stacking.
Data Source
AI summary
The invention relates to a device for a wireless power transfer system. The device comprises a housing and a coil arranged inside the housing. The coil comprises a first conductor wire forming a first sub coil having a plurality of windings and a second conductor wire forming a second sub coil having a plurality of windings. The housing comprises a first holder for accommodating and holding the first sub coil and a second holder for accommodating and holding the second sub coil. The first holder and the second holder are attached to each other such that the first sub coil and the second sub coil together form the coil being arranged between the first holder and the second holder.