Methods and apparatus for reducing flux cancellation in ferrite of double couple inductive power transfer systems

• US 10,377,255 B2
• Filed: 05/13/2016
• Issued: 08/13/2019
• Est. Priority Date: 05/13/2016
• Status: Active Grant

• Current Assignee: WiTricity Corporation
• Original Assignee: WiTricity Corporation
• Inventors: Budhia, Mickel Bipin, Huang, Chang-Yu, Keeling, Nicholas Athol, Kissin, Michael Le Gallais, Beaver, Jonathan
• Primary Examiner(s): Robbins, Jerry D
• Application Number:
  US15/154,286
• Publication Number:
  US 20170326992A1
• Time in Patent Office: 1,187 Days
• Field of Search: 320108
• CPC Class Codes: B60L 5/005 without mechanical contact between the collector and the power supply line
• CPC Class Codes: B60L 53/12 Inductive energy transfer
• CPC Class Codes: H01F 27/24 Magnetic cores
• CPC Class Codes: H01F 27/40 Structural association with built-in electric component, e.g. fuse
• CPC Class Codes: H01F 38/14 Inductive couplings for wireless supply or distribution of electric power using inductive coupling H02J50/10
• CPC Class Codes: H01F 41/0206 Manufacturing of magnetic cores by mechanical means magnetic cores per se H01F27/24
• CPC Class Codes: H01F 41/06 Coil winding
• CPC Class Codes: H02J 50/10 using inductive coupling
• CPC Class Codes: H02J 50/12 of the resonant type
• CPC Class Codes: H02J 50/402 the two or more transmitting or the two or more receiving devices being integrated in the same unit, e.g. power mats with several coils or antennas with several sub-antennas
• CPC Class Codes: H02J 50/50 using additional energy repeaters between transmitting devices and receiving devices
• CPC Class Codes: H02J 7/0042 characterised by the mechanical construction
• CPC Class Codes: H03H 7/38 Impedance-matching networks
• CPC Class Codes: Y02T 10/70 Energy storage systems for electromobility, e.g. batteries
• CPC Class Codes: Y02T 10/7072 Electromobility specific charging systems or methods for batteries, ultracapacitors, supercapacitors or double-layer capacitors
• CPC Class Codes: Y02T 90/12 Electric charging stations
• CPC Class Codes: Y02T 90/14 Plug-in electric vehicles

Abstract

According to some implementations, an apparatus for transmitting charging power wirelessly to a load is provided. The apparatus comprises at least one ferrite structure comprising a first ferrite portion, a second ferrite portion comprising at least a first ferrite leg, a second ferrite leg, and a third ferrite leg, each physically separated from the first ferrite portion by a first distance, and a third ferrite portion positioned between the second ferrite leg and the first ferrite portion and physically contacting the second ferrite leg. The at least one ferrite structure further comprises a coil wound around the second ferrite leg and configured to generate an alternating current under influence of an alternating magnetic field.

Claims

1. An apparatus for transmitting charging power wirelessly to a load, the apparatus comprising:

at least one ferrite structure comprising;

a first ferrite portion,

a second ferrite portion comprising at least a first ferrite leg, a second ferrite leg, and a third ferrite leg, each physically separated from the first ferrite portion by a first distance, and

a third ferrite portion positioned between the second ferrite leg and the first ferrite portion and physically contacting the second ferrite leg;

a coil wound around the second ferrite leg and configured to generate an alternating current under influence of an alternating magnetic field, the coil comprising at least a first winding wound in a first layer around the second ferrite leg and a second winding wound in a second layer around the first layer, the first layer connected to the second layer by a capacitor; and

a control coil wound in a third layer around the coil.

2. The apparatus of claim 1, wherein:

a first air gap separates the first ferrite leg and the first ferrite portion,

a second air gap separates the third ferrite portion and the first ferrite portion,

a third air gap separates the third ferrite leg and the first ferrite portion, and

the second air gap is smaller than each of the first air gap and the third air gap.

3. The apparatus of claim 2, wherein:

a first reluctance path passes through the first ferrite portion, the first air gap, the second ferrite portion, the third ferrite portion and the second air gap,

a second reluctance path passes through the first ferrite portion, the third air gap, the second ferrite portion, the third ferrite portion and the second air gap,

a third reluctance path passes through the first ferrite portion, the first air gap, the second ferrite portion, and the third air gap, and

the third reluctance path provides a higher magnetic reluctance compared to either the first reluctance path and the second reluctance path.

4. The apparatus of claim 3, wherein a first magnetic flux flowing in the third reluctance path is less than a second magnetic flux flowing in the first reluctance path and less than a third magnetic flux flowing in the second reluctance path.

5. The apparatus of claim 1, wherein the at least one ferrite structure comprises a plurality of ferrite structures each substantially the same as the at least one ferrite structure.

6. The apparatus of claim 1, wherein the coil comprises a plurality of layers of windings and a respective capacitor connected in series between each layer of the plurality of layers of windings.

7. The apparatus of claim 1, wherein the first ferrite portion comprises a plurality of interleaved I-shaped ferrite tiles physically separated by a fourth gap, and the second ferrite portion comprises a plurality of interleaved U-shaped ferrite tiles physically separated by a fifth gap.

8. The apparatus of claim 1, further comprising a second coil configured to be driven by the alternating current and wirelessly transmit charging power to the load, the load comprising an electric vehicle.

9. The apparatus of claim 1, wherein the control coil is configured to reduce or prevent generation of the alternating current in the coil in a first configuration, and to allow generation of the alternating current in the coil in a second configuration.

10. The apparatus of claim 9, wherein the control coil includes a switch configured to selectively short-circuit or open-circuit the control coil to switch between the first configuration and the second configuration.

11. The apparatus of claim 1, wherein the alternating magnetic field is generated by at least one of:

a first conductor of an alternating current power backbone disposed in a first space between the first ferrite leg and the second ferrite leg; and

a second conductor of the alternating current power backbone disposed in a second space between the second ferrite leg and the third ferrite leg.

12. A method for transmitting charging power wirelessly to a load, the method comprising:

generating an alternating current via a first coil under influence of a first alternating magnetic field, the first coil wound around at least one portion of a ferrite structure comprising;

a first ferrite portion,

a second ferrite portion comprising at least a first ferrite leg, a second ferrite leg, and a third ferrite leg, each physically separated from the first ferrite portion by a first distance, and

a third ferrite portion positioned between the second ferrite leg and the first ferrite portion and physically contacting the second ferrite leg; and

wirelessly transmitting power via a second alternating magnetic field generated by driving a second coil with the alternating current, wherein one of the first and second coils comprises at least a first winding wound in a first layer around the second ferrite lea and a second winding wound in a second layer around the first layer and has a control coil wound in a third layer around the first or second coil comprising the first and second windings, the first layer connected to the second layer by a capacitor.

13. The method of claim 12, wherein:

a first air gap separates the first ferrite leg and the first ferrite portion,

a second air gap separates the third ferrite portion and the first ferrite portion,

a third air gap separates the third ferrite leg and the first ferrite portion, and

the second air gap is smaller than each of the first air gap and the third air gap.

14. The method of claim 13, wherein:

a first reluctance path passes through the first ferrite portion, the first air gap, the second ferrite portion, the third ferrite portion and the second air gap,

a second reluctance path passes through the first ferrite portion, the third air gap, the second ferrite portion, the third ferrite portion and the second air gap,

a third reluctance path passes through the first ferrite portion, the first air gap, the second ferrite portion, and the third air gap, and

the third reluctance path passing provides a higher magnetic reluctance compared to either the first reluctance path and the second reluctance path.

15. The method of claim 14, wherein a first magnetic flux flowing in the third reluctance path is less than a second magnetic flux flowing in the first reluctance path and less than a third magnetic flux flowing in the second reluctance path.

16. The method of claim 12, wherein the first coil is wound around the second ferrite leg of the ferrite structure and around a second ferrite leg of at least one other ferrite structure substantially the same as the ferrite structure.

17. The method of claim 12, wherein the first coil comprises a plurality of layers of windings and a respective capacitor connected in series between each layer of the plurality of layers of windings.

18. The method of claim 12, wherein the load comprises an electric vehicle configured to receive wireless charging power from the second alternating magnetic field.

19. The method of claim 12, further comprising selectively:

short-circuiting the control coil wound around the at least one portion of the ferrite structure to reduce or prevent generation of the alternating current in the coil; and

open-circuiting the control coil to allow generation of the alternating current in the coil.

20. The method of claim 19, wherein said selectively short-circuiting and open-circuiting the control coil comprises selectively opening and closing a switch.

21. The method of claim 12, wherein the first alternating magnetic field is generated by at least one of:

a first conductor of an alternating current power backbone disposed in a first space between the first ferrite leg and the second ferrite leg; and

a second conductor of the alternating current power backbone disposed in a second space between the second ferrite leg and the third ferrite leg.

22. An apparatus for transmitting charging power wirelessly to a load, the apparatus comprising:

first means for channeling magnetic flux;

second means for channeling magnetic flux comprising at least a first leg, a second leg, and a third leg, each physically separated from the first means for channeling magnetic flux by a first distance, and the second leg being located between the first leg and the third leg;

third means for channeling magnetic flux positioned between the second leg and the first means for channeling magnetic flux and physically contacting the second leg;

means for generating an alternating current under influence of an alternating magnetic field wound around the second leg, the generating means comprising at least a first winding wound in a first layer around the second ferrite leg and a second winding wound in a second layer around the first layer, the first layer connected to the second layer by a capacitor; and

means for reducing or preventing generation of the alternating current wound in a third layer around the means for generating an alternating current under influence of an alternating magnetic field.

23. The apparatus of claim 22, wherein:

a first air gap separates the first leg and the first means for channeling magnetic flux,

a second air gap between the third means for channeling magnetic flux and the first means for channeling magnetic flux,

a third air gap between the third leg and the first means for channeling magnetic flux, and

the second air gap is smaller than each of the first air gap and the third air gap.

24. The apparatus of claim 23, wherein:

a first reluctance path passes through the first means for channeling magnetic flux, the first air gap, the second means for channeling magnetic flux, the third means for channeling magnetic flux and the second air gap,

a second reluctance path passes through the first means for channeling magnetic flux, the second air gap, the second means for channeling magnetic flux and the third air gap,

a third reluctance path passes through the first means for channeling magnetic flux, the first air gap, the second means for channeling magnetic flux, and the third air gap, and

the third reluctance path provides a higher magnetic reluctance compared to either the first reluctance path and the second reluctance path.

25. The apparatus of claim 24, wherein a first magnetic flux flowing in the third reluctance path is less than a second magnetic flux flowing in the first reluctance path and less than a third magnetic flux flowing in the second reluctance path.

26. A method for manufacturing a double couple transformer configured to transmit charging power wirelessly to a vehicle, the method comprising:

providing at least one ferrite structure comprising;

a first ferrite portion,

a second ferrite portion comprising at least a first ferrite leg, a second ferrite leg, and a third ferrite leg, each physically separated from the first ferrite portion by a first distance, and

a third ferrite portion positioned between the second ferrite leg and the first ferrite portion and physically contacting the second ferrite leg;

winding a coil around the second ferrite leg such that the coil is configured to generate an alternating current under influence of an alternating magnetic field, the coil comprising at least a first winding wound in a first layer around the second ferrite leg and a second winding wound in a second layer around the first layer, the first layer connected to the second layer by a capacitor; and

winding a control coil in a third layer around the coil.

27. The method of claim 26, further comprising:

disposing a first conductor of an alternating current power backbone in a first space between the first ferrite leg and the second ferrite leg; and

disposing a second conductor of the alternating current power backbone in a second space between the second ferrite leg and the third ferrite leg.

28. The method of claim 27, further comprising providing at least one other ferrite structure substantially the same as the at least one ferrite structure.

29. The method of claim 27, further comprising connecting a capacitor in series between each layer of windings of the coil.

30. The method of claim 27, further comprising providing the first ferrite portion with a plurality of interleaved I-shaped ferrite tiles physically separated by a fourth gap, and providing the second ferrite portion with a plurality of interleaved U-shaped ferrite tiles physically separated by a fifth gap.