EP0662699B1 - Charging system, and method of making a charging system - Google Patents

Charging system, and method of making a charging system Download PDF

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Publication number
EP0662699B1
EP0662699B1 EP95100242A EP95100242A EP0662699B1 EP 0662699 B1 EP0662699 B1 EP 0662699B1 EP 95100242 A EP95100242 A EP 95100242A EP 95100242 A EP95100242 A EP 95100242A EP 0662699 B1 EP0662699 B1 EP 0662699B1
Authority
EP
European Patent Office
Prior art keywords
partial
turns
coil
inductive charge
charging system
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Expired - Lifetime
Application number
EP95100242A
Other languages
German (de)
English (en)
French (fr)
Other versions
EP0662699A1 (en
Inventor
William Quon
Sam Nakagawa
John T. Hall
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Raytheon Co
Original Assignee
Hughes Aircraft Co
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Hughes Aircraft Co filed Critical Hughes Aircraft Co
Publication of EP0662699A1 publication Critical patent/EP0662699A1/en
Application granted granted Critical
Publication of EP0662699B1 publication Critical patent/EP0662699B1/en
Anticipated expiration legal-status Critical
Expired - Lifetime legal-status Critical Current

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Classifications

    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01FMAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F41/00Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties
    • H01F41/02Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets
    • H01F41/04Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets for manufacturing coils
    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01FMAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F5/00Coils
    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01FMAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F27/00Details of transformers or inductances, in general
    • H01F27/28Coils; Windings; Conductive connections
    • H01F27/2847Sheets; Strips
    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01FMAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F27/00Details of transformers or inductances, in general
    • H01F27/28Coils; Windings; Conductive connections
    • H01F27/2847Sheets; Strips
    • H01F2027/2861Coil formed by folding a blank

Definitions

  • the invention is directed to a charging system comprising an inductive charge coupler connectable with a power source and comprising an inductive charge receptacle into which the inductive charge coupler is insertable, said inductive charge coupler comprising a primary winding and said inductive charge receptacle comprising a secondary winding, said primary winding and/or said secondary winding being a helical induction coil comprising a predetermined number of turns, said turns being made of bendable metal, having a width-to-thickness ratio of greater than 10:1, said turns respectively overlying each other to form said helical induction coil.
  • the invention relates further to a method of making a charging system comprising an inductive charge coupler connectable with a power source and comprising an inductive charge receptacle into which the inductive charge coupler is insertable, said inductive charge coupler comprising a primary winding and said inductive charge receptacle comprising a secondary winding, said primary winding and/or said secondary winding being a helical induction coil with turns having a width-to-thickness ratio greater than 10:1.
  • This kind of charging systems is known in the art (US-A-5,216,402) and is particularly used to charge the battery of a battery-powered vehicle.
  • High frequency electrical conductors carry the principle current near the surface and, in equipment where small size is mandated, thin conductors are required. In addition, high current requires adequate conductive area near the skin. This results in helical coils in an induction structure which have a ratio of width-to-thickness much greater than 10 : 1.
  • a thin but wide helical conductor is required to handle high frequency and high current.
  • High frequency requires conductor thickness to be as little as 0,006 Inch (0,1524 mm) to eliminate unneeded material due to the skin effect. The requirement for high current forces the conductor width to be much greater than ten times the thickness.
  • this object is achieved by:
  • the object is achieved according to the method of making a charging system, mentioned at the outset, by the steps of:
  • the coil starts as a thin sheet of conductor. It is stamped or otherwise cut to form a plurality or arcuate coil segments which are joined to each other on a fold line which is at a right angle to a line from the center of the coil. When the sheet is folded at the fold line, a coil is formed.
  • the arcuate coil sections can be greater or less than 180 degrees. The coil overlaps the fold and is joined at the fold with parent material.
  • It is a further purpose and advantage of this invention to provide a charging system comprising a helical induction coil formed of arcuate segments which are joined together at fold lines of the parent material so that a plurality of arcuate sections can form a several turn coil.
  • It is another purpose and advantage of this invention to provide a method for making a charging system comprising high aspect ratio coil including cutting arcuate coil segments from a thin sheet of electrically conductive material while maintaining the segments joined along fold lines, followed by folding the coil segments together to form a complete circular coil.
  • Fig. 1 illustrates a separable inductive charge coupler 10 which is particularly useful as a structure for supplying power for the charging of a battery in a battery-powered vehicle.
  • a separable inductive charge coupler 10 which is particularly useful as a structure for supplying power for the charging of a battery in a battery-powered vehicle.
  • the power of the batteries is used to propel the automobile and to provide for other power needs thereof.
  • the inductive charge coupler is a transformer primary and contains an appropriate magnetic conductor.
  • the inductive charge receptacle slot contains the secondary winding(s) together with the rest of the magnetic core.
  • the transformer secondary in the automobile is connected through appropriate electrical equipment to the battery for the charging thereof.
  • the frequency is preferably much higher than the ordinary power line frequency for advantageous coupling permitting smaller coupler size, and high charge rates are above 10 kilowatts.
  • the charging connection 10 will be inductive.
  • a transformer primary coil is designed to receive power from a power source and to deliver the power through magnetic coupling to a transformer secondary coil in the automobile.
  • the secondary coil is appropriately connected to charge the automobile batteries.
  • the power supply frequency is chosen in connection with the overall power supply parameters, including the transformer parameters.
  • Inductive charge coupler 12 is seen plugged into the inductive charge receptacle 14 of the automobile in Fig. 1.
  • the coupler 12 is connected to the fixed power source by means of cable 16.
  • the cable 16, seen in Fig. 1 incorporates the electrical cable, coolant tubes (if necessary), and control signal circuitry.
  • inductive charge coupler 12 has a handle 18 by which it can be manually manipulated.
  • the coupler 12 has a panel 20 mounted on the handle 18 so it is manipulated by the handle 18.
  • Panel 20 is supported by a non-magnetic structure extending down from the handle 18, and the panel 20 has a primary winding 22 thereon and a first magnetic core 24 which serves as part of the magnetic circuit.
  • This inductive charge coupler 12 is the unit which is manipulated by the handle 18 and serves as a transformer primary.
  • the inductive charge receptacle 14 is compatible and physically receives the coupler 12 and magnetically couples therewith.
  • the receptacle 14 has a slot (shown schematically) being sized to receive the panel 20 on the coupler 12. It has, further, two secondary windings 30, 32, and has the magnetic structure to complete the magnetic circuit.
  • first magnetic cap 26 has a second core 28 which lies against first core 24.
  • First secondary winding 30 lies around second core 28 and against one lateral side of primary winding 22.
  • Second secondary winding 32 lies against the opposite lateral side of primary winding 22 and around a third core (not shown) of second magnetic cap 34.
  • the magnetic circuit is completed around the sides of the coils 22, 30, 32 by means of four fingers on each of the caps 26, 34 which are in direct contact and engagement. For example, finger 36 on first cap 26 is in direct contact with finger 38 on second cap 34.
  • Receptacle 14 is illustrated as having built-in cooling. There are coolant channels in a first cooling ring 37 and coolant channels in a second cooling ring 39, as seen in Fig. 1. Coolant fluid is supplied, as required to limit temperatures.
  • the primary winding 22 and the secondary windings 30 and 32 are high frequency and high power windings. To achieve efficiency, the windings 22, 30, 32 should be flat but wide coils, as discussed above.
  • Figs. 2, 4 and 6 illustrate blanks from which suitable windings can be made.
  • Figs. 2 and 3 show winding 40, respectively in a configuration as a blank 42 and in the configuration where the blank 42 is almost completely folded into the winding 40.
  • Blank 42 is formed of a group of partial circles which are joined together along fold lines.
  • Partial circles 44, 46, 48, 50, 52 and 54 are illustrated in Fig. 2.
  • Partial circles 44 and 54 respectively, have leads 60 and 62 thereon. These arcuate segments are referred to as partial circles 44 - 54 or as semi-circles, even though in other embodiments including rectangles and squares, they may not subtend 180 degrees. In that sense, the word "semi-circle" is used to indicate a part of a circle rather than half of one. Of course, in Fig.
  • the partial circles 44 - 54 are substantially half circles which extend beyond the half circle subtended arc to permit overlap of the half circles 44 - 54 at fold lines.
  • Fold lines 64, 66, 68, 70, and 72 are shown in Fig. 2.
  • the subtended arc or amount of the partial circle 44 -54 is the radius to the fold line 64 - 72.
  • the fold line 64 - 72 is a line at right angles to the design radius of the partial circle 44 - 54.
  • the design arc of one-half turn, and the radius lines perpendicular to the fold lines 64 - 72 are at 180 degrees to each other.
  • the blank 42 is formed by any convenient means, such as cutting it out of a sheet of electrically conductive metal. It may be electrical copper of a thickness of 0,006 Inch (0,1524 mm). The radial width of each of the partial circular arcs may be 0,500 Inch (12,7 mm) to thus produce a width-to-thickness aspect ratio much greater than 10 : 1.
  • the blank 42 may be cut from the sheet by stamping, die cutting, laser cutting, or other appropriate technique. After the blank 42 is fabricated, the coil 40 is formed by bending the blank 42 on its fold lines 64 - 72 so that the partial circles 44 - 54 subsequently overlie each other to form a helical coil. In Fig.
  • each partial circle 44 - 54 or semi-circle has a subtended arc from the center of the circle to the center of opposite fold lines 64 - 72. In the case of Fig. 2, this arc is 180 degrees. As will be disclosed with respect to Figs. 4 - 7, the arc may be different than 180 degrees.
  • n/A must be less than 0,83.
  • dA/360 integer.
  • Fig. 4 shows a blank 74 being cut from a sheet of winding metal such as sheet copper.
  • the blank 74 has semi-circles 76, 78, 80 and 82, respectively joined by fold lines 84, 86 and 88.
  • the semi-circles 76 and 82 respectively carry leads 90 and 92 for external connection.
  • the fold lines are perpendicular to circle radiuses which are 270 degrees apart. Additionally, the radius in partial circle 76, which extends through the center of lead 90, is at 270 degrees from the radius which is at right angles to fold line 84. This relationship also applies to the positioning of the fold line 88 in lead 92.
  • the coil winding 94 is slightly open to show the fold layers. Normally, the layers would lie against each other.
  • the parts of the winding identified in Fig. 4 are also seen in Fig. 5.
  • d 270 degrees
  • the coil 94 is a 3-turn coil the same as the one illustrated in Fig. 3.
  • utilization the formula: 270 (3/4) 360.
  • Fig. 6 shows a blank 96 from which is folded a 10 turn coil winding 98, shown in Fig. 7.
  • d 300
  • n 10
  • A 12.
  • Lead 100 is integrally formed radially on the end of the semi-circle 102, which is joined to semi-circle 104 at fold line 106.
  • the lead is connected with its center line on a radius, and the fold line 106 is at a right angle to the radius of both semi-circles 102 and 104.
  • These semi-circles continue, joined by fold lines which are at a right angle to the radius through the center of the fold line.
  • the last two semi-circles 108 and 110 are joined at fold line 112.
  • Connector lead 114 is attached to semi-circle 110 on the radius, as previously described.
  • the conductor is supplied with an insulating layer before being folded into helical configuration. This provides insulation between the successive windings. Testing of these folded helical coils indicates that the performance is similar to helical coils made by the rolling process or by the cut-and-solder process.

Landscapes

  • Engineering & Computer Science (AREA)
  • Power Engineering (AREA)
  • Manufacturing & Machinery (AREA)
  • Manufacturing Cores, Coils, And Magnets (AREA)
  • Coils Of Transformers For General Uses (AREA)
  • Coils Or Transformers For Communication (AREA)
  • General Induction Heating (AREA)
EP95100242A 1994-01-10 1995-01-10 Charging system, and method of making a charging system Expired - Lifetime EP0662699B1 (en)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US17917094A 1994-01-10 1994-01-10
US179170 1994-01-10

Publications (2)

Publication Number Publication Date
EP0662699A1 EP0662699A1 (en) 1995-07-12
EP0662699B1 true EP0662699B1 (en) 1998-05-06

Family

ID=22655512

Family Applications (1)

Application Number Title Priority Date Filing Date
EP95100242A Expired - Lifetime EP0662699B1 (en) 1994-01-10 1995-01-10 Charging system, and method of making a charging system

Country Status (7)

Country Link
EP (1) EP0662699B1 (enrdf_load_stackoverflow)
JP (1) JPH07263260A (enrdf_load_stackoverflow)
KR (1) KR950024222A (enrdf_load_stackoverflow)
DE (1) DE69502301T2 (enrdf_load_stackoverflow)
ES (1) ES2115990T3 (enrdf_load_stackoverflow)
NO (1) NO950083L (enrdf_load_stackoverflow)
TW (1) TW256924B (enrdf_load_stackoverflow)

Cited By (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN104008867A (zh) * 2014-06-09 2014-08-27 信源电子制品(昆山)有限公司 金属片线圈及其制作方法、电感器、变压器、无线充电器
US11049638B2 (en) 2016-08-31 2021-06-29 Vishay Dale Electronics, Llc Inductor having high current coil with low direct current resistance
USD1034462S1 (en) 2021-03-01 2024-07-09 Vishay Dale Electronics, Llc Inductor package

Families Citing this family (19)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB2332100A (en) * 1997-12-02 1999-06-09 David Vail An insulated winding arrangement
US6222437B1 (en) * 1998-05-11 2001-04-24 Nidec America Corporation Surface mounted magnetic components having sheet material windings and a power supply including such components
US6204745B1 (en) * 1999-11-15 2001-03-20 International Power Devices, Inc. Continuous multi-turn coils
ATE255271T1 (de) * 2001-06-21 2003-12-15 Magnetek Spa Kreisförmige flachspulen sowie induktives bauelement, welches mit einer oder mehreren dieser spulen hergestellt wird
US6985062B2 (en) * 2002-09-13 2006-01-10 Matsushita Electric Industrial Co., Ltd. Coil component and method of producing the same
JP2009105158A (ja) * 2007-10-22 2009-05-14 Tokyo Coil Engineering Kk インダクタ用コイル構造及びインダクタ
CN101645345B (zh) * 2008-08-07 2012-09-19 台达电子工业股份有限公司 导电绕组结构
JP5857809B2 (ja) * 2012-03-09 2016-02-10 株式会社オートネットワーク技術研究所 コイル
DE102012207228A1 (de) * 2012-05-02 2013-11-07 Robert Bosch Gmbh Kupfer-Flachwicklung zur Erzeugung magnetischer Felder in elektrischen Energiewandlern mit hohen Füllfaktoren
TWI475579B (zh) * 2012-12-14 2015-03-01 Ghing Hsin Dien 線圈
TWI490893B (zh) * 2013-04-26 2015-07-01 Ghing Hsin Dien 線圈
JP2015188033A (ja) * 2014-03-27 2015-10-29 パナソニックIpマネジメント株式会社 薄型コイル及びトランス
US9583433B2 (en) * 2015-02-25 2017-02-28 Qualcomm Incorporated Integrated device package comprising conductive sheet configured as an inductor in an encapsulation layer
DE102017207659B4 (de) * 2017-05-08 2019-11-14 Audi Ag Elektrische Maschine sowie Verfahren zum Herstellen einer elektrischen Maschine
AU2018390986B2 (en) * 2017-12-22 2023-03-16 Tritium Power Solutions Pty Ltd A coil assembly for use in a common mode choke
JP7124429B2 (ja) * 2018-05-09 2022-08-24 Tdk株式会社 コイル部品およびコイル装置
CN111292933B (zh) * 2018-12-25 2025-07-22 东莞市海默生电子有限公司 用于绕组的无焊嵌入式铜圈、弯折模具、及制造方法
US11948724B2 (en) 2021-06-18 2024-04-02 Vishay Dale Electronics, Llc Method for making a multi-thickness electro-magnetic device
CN113963884B (zh) * 2021-11-05 2024-05-03 国网陕西省电力公司宝鸡供电公司 电缆中间导体连接管电磁脉冲成形用叠片式可开合线圈

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DE148789C (enrdf_load_stackoverflow) *
GB191329274A (en) * 1913-12-19 1915-02-04 John William Ewart Improvements in Current Carrying Coils for Electro-magnetic Apparatus.
JPS55132007A (en) * 1979-04-02 1980-10-14 Matsushita Electric Works Ltd Thick winding coil
JPS5923510A (ja) * 1982-07-30 1984-02-07 Hitachi Ltd 電気機器用コイルの製造方法
JPS61184806A (ja) * 1985-02-12 1986-08-18 Tokyo Kosumosu Denki Kk らせん状コイル
DE3643044A1 (de) * 1986-12-17 1988-06-30 Ivan Bystrican Faltspule
JPH05217770A (ja) * 1992-01-31 1993-08-27 Sony Corp トランス装置

Cited By (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN104008867A (zh) * 2014-06-09 2014-08-27 信源电子制品(昆山)有限公司 金属片线圈及其制作方法、电感器、变压器、无线充电器
US11049638B2 (en) 2016-08-31 2021-06-29 Vishay Dale Electronics, Llc Inductor having high current coil with low direct current resistance
US11875926B2 (en) 2016-08-31 2024-01-16 Vishay Dale Electronics, Llc Inductor having high current coil with low direct current resistance
USD1034462S1 (en) 2021-03-01 2024-07-09 Vishay Dale Electronics, Llc Inductor package
USD1077746S1 (en) 2021-03-01 2025-06-03 Vishay Dale Electronics, Llc Inductor package

Also Published As

Publication number Publication date
TW256924B (enrdf_load_stackoverflow) 1995-09-11
EP0662699A1 (en) 1995-07-12
DE69502301D1 (de) 1998-06-10
ES2115990T3 (es) 1998-07-01
KR950024222A (ko) 1995-08-21
JPH07263260A (ja) 1995-10-13
NO950083D0 (no) 1995-01-09
DE69502301T2 (de) 1998-09-03
NO950083L (no) 1995-07-11

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