Patent Application
20230339337
Embodiments relate to a wireless charging device and to a transportation means (vehicle) comprising the same. More specifically, the embodiments relate to a wireless charging device with an appropriate thickness, enhanced charging efficiency, and minimized heat generation and to a transportation means comprising the same such as an electric vehicle.
In recent years, the information and communication field is being developed at a very fast pace, and various technologies that comprehensively combine electricity, electronics, communication, and semiconductor are continuously being developed. In addition, as electronic devices tend to he more mobile, research on wireless communication and wireless power transmission technologies is being actively conducted in the communication field. In particular, research on a method for wirelessly transmitting power to electronic devices is being actively conducted.
The wireless power transmission refers to wirelessly transmitting power through space using inductive coupling, capacitive coupling, or an electromagnetic field resonance structure such as an antenna without physical contact between a transmitter that supplies power and a receiver that receives power. The wireless power transmission is suitable for portable communication devices, electric vehicles, and the like that require a large-capacity battery. Since the contacts are not exposed, there is little risk of a short circuit, and a charging failure phenomenon in a wired method can be prevented.
Meanwhile, as interest in electric vehicles has rapidly increased in recent years, interest in building charging infrastructure is increasing. Various charging methods have already appeared, such as electric vehicle charging using home chargers, battery replacement, rapid charging devices, and wireless charging devices. A new charging business model has also begun to appear (see Korean Laid-open Patent Publication No. 2011-0042403). In addition, electric vehicles and charging stations that are being tested begin to stand out in Europe. In Japan, electric vehicles and charging stations are being piloted, led by automakers and power companies.
(Patent Document 1) Korean Laid-open Patent Publication No. 2011-0042403
A wireless charging device used as a transceiver in a transportation means such as an electric vehicle is provided with a coil unit, a magnetic unit, and a shield unit, and the performance of the device varies depending on various variables such as the distance between them and each size and component.
Referring to
In particular, as shown in
As a result of research conducted by the present inventors, it has been discovered that if the distance between a magnetic unit and a shield unit is adjusted such that the Q factor calculated in consideration of inductance and resistance together has the maximum rate of increase, the wireless charging device has an appropriate thickness, high charging efficiency, and minimized heat generation. In addition, as a result of experiments on wireless charging devices of various specifications and materials, the present inventors have been able to formulate a specific formula for a preferred range of characteristics including the distance between a magnetic unit and a coil unit and a Q factor.
Accordingly, the object of the embodiments is to provide a wireless charging device in Which such characteristics as the distance between a magnetic unit and a shield unit and a Q factor are formulated to a specific formula so as to have an appropriate thickness, high charging efficiency, and minimized heat generation, and a transportation means comprising the same.
According to an embodiment, there is provided a wireless charging device, which comprises a coil unit comprising a conductive wire; a magnetic unit disposed on the coil unit; and a shield unit disposed on the magnetic unit, wherein the following Relationship (1) is satisfied:
1.1≤[(ΔQ1−ΔQ2)/Q]×100 (1)
Here, ΔQ1 is (Q−Qa)/Δd, ΔQ2 is (Qb−Q)/Δd, Q is the Q factor of the wireless charging device measured at a frequency of 85 kHz, Qa is the Q factor measured when the distance between the magnetic unit and the shield unit in the wireless charging device is further decreased by Δd (mm), Qb is the Q factor measured when the distance between the magnetic unit and the shield unit in the wireless charging device is further increased by Δd (mm), and the Q factor is calculated as 2×π×f×L/R, wherein f is the frequency (kHz), L is the inductance (μH) of the coil unit, and R is the resistance (mΩ) of the coil unit. Q, Qa, Qb, f, L, R, ΔQ1, ΔQ2, and Δd are numerical values without respective units.
According to another embodiment, there is provided a transportation means comprising the wireless charging device according to an embodiment.
As the wireless charging device according to the embodiment satisfies a specific formula in which such characteristics as the distance between the magnetic unit and the shield unit and the Q factor are taken into account, it can have an appropriate thickness, high charging efficiency, and minimized heat generation.
Accordingly, the wireless charging device according to the embodiment can be advantageously used in a transportation means such as electric vehicles that requires large-capacity power transmission between a transmitter and a receiver.
In the following description of the embodiments, in the case where an element is mentioned to be disposed “on” or “under” another element, it means not only that one element is directly formed “on” or “under” another element, but also that one element is indirectly disposed. on or under another element with other elements) interposed between them.
In this specification, the upper/lower relationship of the respective components is described with reference to the accompanying drawings for easy understanding. However, when an object is observed in a manner different from the drawing, it should be understood that the upper/lower relationship of the components varies depending on the direction of observation. In addition, for the sake of description, the sizes of individual elements in the appended drawings may be exaggeratedly depicted, and they may differ from the actual sizes.
Throughout the present specification, when a part is referred to as “comprising” an element, it is understood that other elements may be comprised, rather than other elements are excluded, unless specifically stated otherwise.
In addition, all numbers expressing the physical properties, dimensions, and the like of elements used herein are to be understood as being modified by the term “about” unless otherwise indicated.
In the present specification, a singular expression is understood to encompass a singular or plural expression, interpreted in context, unless otherwise specified.
The wireless charging device (10) according to an embodiment of the present invention comprises a coil unit (200) comprising a. conductive wire; a magnetic unit (300) disposed on the coil unit (200) and a shield unit (400) disposed on the magnetic unit (300). In addition, the wireless charging device (10) may further comprise a support unit (100) for supporting the coil unit (200) and a housing (610, 620, 630) for protecting the components.
According to an embodiment, the wireless charging device satisfies the following Relationship (1):
1.1≤[(ΔQ1−ΔQ2)/Q]×100 (1)
Here, ΔQ1 is (Q−Qa)/Δd, ΔQ2 is (Qb−Q)/Δd, Q is the Q factor of the wireless charging device measured at a frequency of 85 kHz, Qa is the Q factor measured when the distance between the magnetic unit and the shield unit in the wireless charging device is further decreased by Δd (mm), Qb is the Q factor measured when the distance between the magnetic unit and the shield unit in the wireless charging device is further increased by Δd (mm), and the Q factor is calculated as 2×π×f×L/R, wherein f is the frequency (kHz), L is the inductance (μH) of the coil unit, and R is the resistance (mΩ) of the coil unit. Q, Qa, Qb, f, L, R, ΔQ1, ΔQ2, and Δd are numerical values without respective units.
Inductance (μH), resistance (mΩ), and distance (mm), excluding the Q factor, among the characteristics used in Relationship (1) have their own units. However, numerical values alone without units are used in Relationship (1). Therefore, the calculated value in Relationship (1) does not have a unit as well.
In addition, in the present specification, it should be taken into account that the measured or calculated values of inductance, resistance, and Q factor may have slight errors in the measurement equipment or calculation process, for example, within about 0.5%.
The Q factor is also called a quality factor as is well known in the art, and it stands for quality according to a frequency of a current or a resonance frequency in a resonance circuit. Since the Q factor is calculated as a ratio of energy stored in a resonator and energy lost, the higher the Q factor, the better the resonance characteristics at a corresponding frequency. The Q factor may be calculated from inductance and resistance measured through the coil unit using an LCR meter at a specific frequency, and it is a value without a unit.
In addition, Δd is not particularly limited, but it may be, for example, 0.1 mm or more, 0.3 mm or more. 0.5 mm or more. 1 mm or more, or 2.5 mm or more, and 3 mm or less, 2.5 mm or less, 2 mm or less, 1.5 mm or less, 1 mm or less, or 0.5 mm or less. Specifically, Δd may be 0.1 mm to 3 mm, 0.3 mm to 2.5 mm, or 0.5 mm to 2 mm. As a more specific example, Δd may be 0.5 mm, 1 mm, 1.5 mm, 2 mm, 3 mm, or 4 mm.
Since the Q factor is a characteristic in which inductance and resistance are taken into account together, if the distance between the magnetic unit and the shield unit is adjusted such that the Q factor has the maximum rate of increase, the wireless charging device can have an appropriate thickness, high charging efficiency, and minimized heat generation. The location at which the Q factor has the maximum rate of increase as discussed above may be identified as the location at which the value obtained by subtracting ΔQ2 from ΔQ1 is maximized. Here, the overall level of the Q factor varies depending on the detailed components of the wireless charging device; thus, the value obtained by subtracting ΔQ2 from ΔQ1 may also vary significantly. However, if the value obtained by subtracting ΔQ2 from ΔQ1 is divided by the Q factor of the wireless charging device, an alternative normalization value may be derived. Accordingly, a desirable value range may be derived regardless of the detailed configuration of the device. According to the embodiment, this technical idea is presented through a specific formula, that is, Relationship (1).
If the calculated value of Relationship (1) is 1.1 or more, it has a significant technical effect in terms of the thickness, charging efficiency, and heat generation of the wireless charging device. If it is less than this value, for example, if it is 1.0 or less, the technical effect may be insignificant or rather deteriorated. For example, the calculated value of Relationship (1) may be 1.5 or more, 2.0 or more, 2.5 or more, 3.0 or more, 3.5 or more, 4.0 or more, 4.5 or more, or 5.0 or more. Meanwhile, the upper limit of the calculated value of Relationship (1) is not particularly limited. But the calculated value of Relationship (1) may be, for example, 20 or less, 10 or less, 8 or less, 7 or less, or 6 or less. Specifically, the calculated value in Relationship (1) may be 1.1 to 20, 1.1 to 10, 1.1 to 8, 1.1 to 7, or 1.1 to 6.
The wireless charging device may have a high Q factor in the vicinity of a standard frequency for wireless charging of an electric vehicle. The standard frequency for wireless charging of an electric vehicle may be less than 100 kHz, for example, 79 kHz to 90 kHz, specifically, 81 kHz to 90 kHz, more specifically, about 85 kHz. It is a band distinct from the frequency applied to mobile electronic devices such as cell phones.
The wireless charging device may have a Q factor of 300 or more at a frequency of 85 kHz. For example, the Q factor of the wireless charging device may be 350 or more, 400 or more, 430 or more, 450 or more, 500 or more, 550 or more, 600 or more, 620 or more, or 630 or more at a frequency of 85 kHz. in addition, the upper limit of the Q factor of the wireless charging device is not particularly limited, but the Q factor may be, for example, 1,000 or less, 900 or less, 800 or less, 700 or less, 600 or less, or 500 or less.
The Q factor of the wireless charging device may vary depending on the materials and arrangements of the respective components. For example, the Q factor of the wireless charging device may vary depending on whether the material of the magnetic unit is composed of a sintered ferrite material or a polymer-based magnetic material. In addition, since the inductance and resistance of the coil unit vary depending on the diameter of the conductive wire that constitutes the coil unit or the number of turns of the conductive wire, the Q factor may also vary accordingly.
According to another embodiment, the wireless charging device satisfies the following Relationship (2).
−1.1≥[(ΔR1−ΔR2)/R]×100 (2)
Here, ΔR1 is (R−Ra)/Δd, ΔR2 is (Rb−R)/Δd, R is the resistance (mΩ) of the coil unit measured at a frequency of 85 kHz, Ra is the resistance (mΩ) measured when the distance between the magnetic unit and the shield unit is further decreased by Δd (mm), and Rb is the resistance (mΩ) measured when the distance between the magnetic unit and the shield unit is further increased by Δd (mm). R, Ra, Rb, ΔR1, ΔR2, and Δd are numerical values without respective units.
Resistance (mΩ) and distance (mm) among the characteristics used in Relationship (2) have their own units. However, numerical values alone without units are used in Relationship (2). Therefore, the calculated value in Relationship (2) does not have a unit as well.
In Relationship (2), Δd may be determined within the range exemplified in Relationship (1) above, and it may be 2 mm as a specific example.
When the resistance of the coil unit, which changes according to the distance between the magnetic unit and the shield unit, is represented as a curve, the resistance of the coil unit at a distance (V) between the magnetic unit and the shield unit, a distance (Va) decreased by Δd (mm), and a distance (Vb) increased by Δd (mm), respectively, may be referred to as R, Ra, and Rb. Here, ΔR1 is the rate of change (slope of the curve) of the resistance in the interval (Δd) between Va−V, and ΔR2 is the rate of change (slope of the curve) of the resistance in the interval (Δd) between V−Vb.
The resistance of the coil unit in a wireless charging device intensifies heat generation. Thus, when the distance between the magnetic unit and the shield unit is adjusted such that the resistance of the coil unit has the maximum rate of decrease, heat generation can be minimized while the wireless charging device has an appropriate thickness. The location at which the resistance of the coil unit has the maximum rate of decrease as discussed above may be identified as the location at which the value obtained by subtracting ΔR2 from ΔR1 is minimized. Here, the level of the resistance of the coil unit varies depending on the detailed components of the wireless charging device; thus, the value obtained by subtracting ΔR2 from ΔR1 may also vary depending on the devices. However, if the value obtained by subtracting ΔR2 from ΔR1 is divided by the resistance of the coil unit, an alternative normalization value may be derived. Accordingly, a desirable value range may be derived regardless of the detailed configuration of the device. According to the embodiment, this technical idea is presented through a specific formula, that is, Relationship (2).
If the calculated value of Relationship (2) is −1.1 or less, it has a significant technical effect in terms of the thickness and heat generation of the wireless charging device. If it is greater than this value, for example, if it is −1.0 or more, the technical effect may be insignificant or rather deteriorated. For example, the calculated value of Relationship (2) may be −1.5 or less, −2.0 or less, −2.5 or less, −3.0 or less, −3.5 or less, 4.0 or less, −4.5 or less, or −5.0 or less. Meanwhile, the lower limit of the calculated value of Relationship (2) is not particularly limited. But the calculated value of Relationship (2) may be, for example, −20 or more, −10 or more, −8 or more, −7 or more, or −6 or more. Specifically, the calculated value in Relationship (2) may be −20 to −1.1, −10 to −1.1, −8 to −1.1 −7 to −1,1, or −6 to −1.1.
The resistance of the coil unit may be 40 mΩ or more, 50 mΩ or more, 60 mΩ or more, or 70 mΩ more, and 100 mΩ or less, 90 mΩ or less, 80 mΩ or less, or 70 mΩ or less at a frequency of 85 kHz. Specifically, it may be 45 mΩ to 75 mΩ or 65 mΩ to 95 mΩ, but it is not limited thereto.
According to still another embodiment, the wireless charging device satisfies the following Relationship (3).
0.1≤[(L1−ΔL2)/L]×100 (3)
Here, ΔL1 is (L−La)/Δd, ΔL2 is (Lb−L)/Δd, L is the inductance (μH) of the coil unit measured at a frequency of 85 kHz, La is the inductance (μH) measured when the distance between the magnetic unit and the shield unit is further decreased by Δd (mm), and Lb is the inductance (μH) measured when the distance between the magnetic unit and the shield unit is further increased by Δd (mm). L, La, Lb, ΔL1, ΔL2, and Δd are numerical values without respective units.
Inductance (μH) and distance (mm) among the characteristics used in Relationship (3) have their own units. However, numerical values alone without units are used in Relationship (3). Therefore, the calculated value in Relationship (3) does not have a unit as well.
In Relationship (3), Δd may be determined within the range exemplified in Relationship (1) above, and it may be 2 mm as a specific example.
When the inductance of the coil unit, which changes according to the distance between the magnetic unit and the shield unit, is represented as a curve, the inductance of the coil unit at a distance (V) between the magnetic unit and the shield unit, a distance (Va) decreased by Δd (mm), and a distance (Vb) increased by Δd (mm), respectively, may be referred to as L, La and Lb. Here, ΔL1 is the rate of change (slope of the curve) of the inductance in the interval (Δd) between Va−V, and ΔL2 is the rate of change (slope of the curve) of the inductance in the interval (Δd) between V−Vb.
The inductance of the coil unit in a wireless charging device is generally proportional to the charging efficiency. Thus, when the distance between the magnetic unit and the shield unit is adjusted such that the inductance of the coil unit has the maximum rate of increase, charging efficiency can he maximized while the wireless charging device has an appropriate thickness. The location at which the inductance of the coil unit has the maximum rate of increase as discussed above may be identified as the location at which the value obtained by subtracting ΔL2 from ΔL1 is maximized. Here, the level of the inductance of the coil unit varies depending on the detailed components of the wireless charging device; thus, the value obtained by subtracting ΔL2 from ΔL1 may also vary depending on the devices. However, if the value obtained by subtracting ΔL2 from ΔL1 is divided by the inductance of the coil unit, an alternative normalization value may be derived. Accordingly, a desirable value range may be derived regardless of the detailed configuration of the device. According to the embodiment, this technical idea is presented through a specific formula, that is, Relationship (3).
If the calculated value of Relationship (3) is 0.1 or more, it has a significant technical effect in terms of the thickness and charging efficiency of the wireless charging device. If it is less than this value, for example, if it is 0 or less, the technical effect may be insignificant or rather deteriorated. For example, the calculated value of Relationship (3) may be 0.2 or more, 0.3 or more, 0.4 or more, 0.5 or more, 0.6 or more, 0.7 or more, 0.8 or more, or 0.9 or more. Meanwhile, the upper limit of the calculated value of Relationship (3) is not particularly limited. But the calculated value of Relationship (3) may be, for example, 5 or less, 3 or less, 2 or less, 1.5 or less, or 1.3 or less. Specifically, the calculated value in Relationship (3) may be 0.1 to 5, 0.1 to 3, 0.1 to 2, 0.1 to 1.5, or 0.1 to 1.3.
The inductance of the coil unit may be 30 μH or more, 40 μH or more, 45 μH or more, 50 μH or more, 70 μH or more, or 90 μH or more, and 120 μH or less, 110 μH or less, 100 μH or less, 80 μH or less, 60 μH or less, or 50 μH or less at a frequency of 85 kHz. Specifically, it may be 30 μH to 60 μH or 70 μH to 120 μH, but it is not particularly limited thereto.
As a specific example, the coil unit may have an inductance of 45 μH or more and a resistance of 80 mΩ or less at a frequency of 85 kHz, and the wireless charging device may have a Q factor of 350 or more at a frequency of 85 kHz. However, the inductance and resistance of the coil unit may vary depending on the type of the coil unit and the distance between the magnetic unit and the shield unit, and they are not limited to the ranges exemplified above.
Referring to
Specifically, the distance between the magnetic unit and the shield unit may be 1 mm or more, 2 mm or more, 3 mm or more, 3.5 mm or more, 4 mm or more, 4.5 mm or more, or 5 mm or more. In addition, the distance between the magnetic unit and the shield unit may be 9 mm or less, 7 mm or less, 6.5 mm or less, 6 mm or less, 5.5 mm or less, or 5 mm or less. For example, the distance between the magnetic unit and the shield unit may be 1 mm to 9 mm, 3 mm to 7 mm, 3.5 mm to 6.5 mm, 4 mm to 6 mm, 4.5 mm to 5.5 mm, 5 mm to 7 mm, or 3 mm to 5 mm. More specifically, the distance between the magnetic unit and the shield unit may be 4 mm to 6 mm.
In addition, the distance (D) between the coil unit (200) and the magnetic unit (300) may be adjusted within a certain range. For example, as the magnetic unit is spaced apart from the coil unit, the inductance decreases, thereby reducing the Q factor of the wireless charging device, which causes a decrease in charging efficiency and an increase in heat generation. On the other hand, as the distance between the coil unit and the magnetic unit is closer, the inductance is increased, whereas it is difficult to assemble the coil and the magnetic body that are in close contact, and it may be vulnerable to external impact.
For example, the distance between the coil unit and the magnetic unit may be greater than 0 mm, 1 mm or more, 1.5 mm or more, 2 mm or more, or 2.5 mm or more. In addition, the distance between the coil unit and the magnetic unit may be 10 mm or less, 5 mm or less, 4 mm or less, 3.5 mm or less, 3 mm or less, or 2.5 mm or less. For example, the distance between the coil unit and the magnetic unit may be 1 mm to 5 mm, 1 mm to 3 mm, 1.5 mm to 4 mm, 1.5 mm to 3.5 mm, 1.5 mm to 2.5 mm, 2 mm to 3.5 mm, or 2.5 mm to 3.5 mm. More specifically, the distance between the coil unit and the magnetic unit may be 1 mm to 3 mm.
The coil unit comprises a conductive wire. The conductive wire comprises a conductive material. For example, the conductive wire may comprise a conductive metal. Specifically, the conductive wire may comprise at least one metal selected from the group consisting of copper, nickel, gold, silver, zinc, and tin.
The conductive wire may be a litz wire in which a plurality of fine strands are twisted and then covered. For example, the litz wire may be composed of 10 or more, 100 or more, or 500 or more fine strands. Specifically, it may be composed of 500 to 1,500 fine strands.
In addition, the conductive wire may be covered with an insulating sheath. For example, the insulating sheath may comprise an insulating polymer resin. Specifically, the insulating sheath may comprise a poly vinyl chloride (PVC) resin, a polyethylene (PE) resin, a Teflon resin, a silicone resin, a polyurethane resin, or the like.
The conductive wire may be wound in the form of a planar coil. Specifically, the planar coil may comprise a planar spiral coil. In addition, the planar shape of the coil unit may be a circle, an ellipse, a polygon, or a polygonal shape with rounded corners, but it is not particularly limited thereto.
Specifically, the outer dimension (Od) of the coil unit (200) may be 50 mm to 1,000 mm, 100 mm to 500 mm, 100 mm to 300 mm, 200 mm to 800 mm, 300 mm to 400 mm, or 500 mm to 1,000 mm. In addition, the inner dimension (Id) of the coil unit may be 5 mm to 300 mm, 10 mm to 200 mm, 100 mm to 200 mm, 150 mm to 250 mm, or 20 mm to 150 mm.
The number of turns of the conductive wire wound in the planar coil may be 5 to 50 times, 10 to 30 times, 5 to 30 times, 15 to 50 times, or 20 to 50 times.
As a specific example; the coil unit is a planar spiral coil in which the conductive wire is wound 5 to 15 times and may have an outer dimension of 300 mm to 400 mm and an inner dimension of 150 mm to 250 mm.
Within the preferred dimensions and specification ranges of the planar coil as described above, it can be appropriately used in the fields such as electric vehicles that require large-capacity power transmission.
The distance between the conductive wires in the planar coil shape may he 0.1 cm to 1 cm, 0.1 cm to 0.5 cm, or 0.5 cm to 1 cm.
Referring to
The magnetic unit is disposed on the coil unit to increase wireless charging efficiency.
The material of the magnetic unit is not particularly limited and may he a magnetic material used in a wireless charging device.
For example, the magnetic unit may comprise at least one of a ferrite magnetic material and a polymer-type magnetic material.
As an example, the magnetic unit may comprise a ferrite-based magnetic material. For example, the specific chemical formula of the ferrite-based magnetic material may be represented by MOFe2O3 (wherein M is one or more divalent metal elements such as Mn, Zn, Cu, and Ni). Specifically, the magnetic unit preferably comprises a sintered ferrite-based magnetic material from the viewpoint of such magnetic characteristics as magnetic permeability. The sintered magnetic material may be prepared in the form of a sheet or a block by mixing raw materials, followed by calcining, pulverizing, mixing with a binder resin, molding, and sintering. Specifically, the ferrite-based magnetic material may comprise a Ni—Zn-based, Mg—Zn-based, or Mn—Zn-based ferrite. In particular, Mn—Zn-based ferrite may exhibit high magnetic permeability, low magnetic permeability loss, and high saturation magnetic flux density over a temperature range of room temperature to 100° C. or higher at a frequency of 85 kHz.
As another example, the magnetic unit may comprise a polymer resin and a magnetic powder dispersed in the polymer resin. As a result, since the magnetic powder is coupled with each other by the polymer resin, the magnetic unit may have fewer defects over a large area and less damage caused by an impact. The magnetic powder may be an oxide-based magnetic powder, a metal-based magnetic powder, or a mixed powder thereof. For example, the oxide-based magnetic powder may be a ferrite-based powder, specifically, a Ni—Zn-based, Mg—Zn-based, or Mn—Zn-based ferrite powder. In addition, the metal-based magnetic powder may be a Fe—Si—Al alloy magnetic powder or a Ni—Fe alloy magnetic powder, more specifically, a sendust powder or a permalloy powder. In addition, the magnetic powder may be a nanocrystalline magnetic powder. For example, it may be a Fe-based nanocrystalline magnetic powder. Specifically, it may be a Fe—Si—Al-based nanocrystalline magnetic powder, a Fe—Si—Cr-based nanocrystalline magnetic powder, or a Fe—Si—B—Cu—Nb-based nanocrystalline magnetic powder. The magnetic powder may have an average particle diameter in the range of 3 nm to 1 mm, 1 μm to 300 μm, 1 μm to 50 μm, or 1 μm to 10 μm. The magnetic unit may comprise the magnetic powder in an amount of 10% by weight or more, 50% by weight or more, 70% by weight or more, or 85% by weight or more. For example, the magnetic unit may comprise the magnetic powder in an amount of 10% by weight to 99% by weight, 10% by weight to 95% by weight, or 50% by weight to 95% by weight. Examples of the polymer resin include a polyimide resin, a polyamide resin, a polycarbonate resin, an acrylonitrile-butadiene-styrene (ABS) resin, a polypropylene resin, a polyethylene resin, a polystyrene resin, a polyphenylsulfide (PSS) resin, a polyether ether ketone (PEEK) resin, a silicone resin, an acrylic resin, a polyurethane resin, a polyester resin, an isocyanate resin, and an epoxy resin, but it is not limited thereto.
The magnetic unit may have a sheet shape or a block shape. Referring to
The magnetic unit may have a shape extending in a direction parallel to the coil unit. For example, the magnetic unit may have a flat sheet shape, the coil unit may have a planar coil shape, and the magnetic unit and the coil unit may be disposed parallel to each other. The planar shape of the magnetic unit may be a polygon, a polygon with rounded corners, or a circular shape. For example, when the magnetic unit has a shape of a square sheet, the length of one side may be 100 mm to 700 mm, 200 mm to 500 mm, or 300 mm to 350 mm. As a specific example, the magnetic unit may be a rectangular sheet having a side length of 300 mm to 350 mm and a thickness of 3 mm to 7 mm.
The magnetic unit may have magnetic characteristics of a certain level in the vicinity of a standard frequency for wireless charging of an electric vehicle. The magnetic permeability of the magnetic unit at 85 kHz may vary depending on the material. It may be 5 or more, for example, 5 to 150,000 and may specifically be in the range of 5 to 300, 500 to 3,500, or 10,000 to 150,000, depending on the specific material. In addition, the magnetic permeability loss of the magnetic unit at 85 kHz may vary depending on the material. It may be 0 or more, for example, 0 to 50,00 and may specifically be 0 to 1,000, 1 to 100, 100 to 1,000, or 5,000 to 50,000, depending on the specific material.
The shield unit is disposed on the magnetic unit to suppress electromagnetic interference (EMI) that may be generated by the leakage of electromagnetic waves to the outside through electromagnetic shielding.
The shield unit may be disposed to be spaced apart from the coil unit by a predetermined interval. For example, the spaced distance between the shield unit and the coil unit may be 10 mm or more or 15 mm or more, specifically, 10 mm to 30 mm or 10 mm to 20 mm.
The shield unit may comprise a metal. Specifically, the shield unit may be a metal plate, but it is not particularly limited thereto. As a specific example, the material of the shield unit may be aluminum. Other metals or alloy materials having an electromagnetic wave shielding capability may be used.
Referring to
The shield unit may have a shape extending in a direction parallel to the magnetic unit. For example, the magnetic unit and the shield unit may have a flat sheet shape and may be disposed parallel to each other. The planar shape of the shield unit may be a polygon, a polygon with rounded corners, or a circular shape. For example, when the shield unit has a shape of a square sheet, the length of one side may be 100 mm to 700 mm, 200 mm to 500 mm, or 300 mm to 400 mm. As a specific example, the shield unit may be a rectangular sheet having a side length of 300 mm to 400 mm and a thickness of 1 mm to 3 mm.
Referring to
In addition, the wireless charging device (10) according to an embodiment may further comprise a spacer for securing a space between the shield unit (1400) and the magnetic unit (300). The material and structure of the spacer may he a material and structure of a conventional spacer used in a wireless charging device.
The wireless charging device (10) according to an embodiment may further comprise a housing (600) for protecting the components described above. For example, the housing may have a configuration in which a lower housing (610), a lateral housing (620), and an upper housing (630) are combined, but it is not particularly limited thereto.
The housing allows such components as the coil unit, the shield unit, and the magnetic unit to be properly disposed and assembled. The material and structure of the housing may be a material and structure of a conventional housing used in a wireless charging device. For example, the housing may be manufactured using a plastic material having excellent durability.
The wireless charging device can be advantageously used in a transportation means such as electric vehicles that requires large-capacity power transmission between a transmitter and a receiver.
In addition, the wireless charging device may be applied to a station (or charging station) that transmits wireless power in response to the transportation means. That is, the station according to an embodiment may also comprise a wireless charging device having the configuration and characteristics as described above.
Referring to
The transportation means according to an embodiment comprises a wireless charging device, wherein the wireless charging device comprises a coil unit comprising a conductive wire; a magnetic unit disposed on the coil unit; and a shield unit disposed on the magnetic unit, wherein the following Relationship (1):
1.1≤[(ΔQ1−ΔQ2)/Q]×100 (1)
Here, ΔQ1 is (Q−Qa)/Δd, ΔQ2 is (Qb−Q)/Δd, Q is the Q factor of the wireless charging device measured at a frequency of 85 kHz, Qa is the Q factor measured when the distance between the magnetic unit and the shield unit in the wireless charging device is further decreased by Δd (mm), Qb is the Q factor measured When the distance between the magnetic unit and the shield unit in the wireless charging device is further increased by Δd (mm), and the Q factor is calculated as 2×π×f×L/R, wherein f is the frequency (kHz), L is the inductance (μH) of the coil unit, and R is the resistance (mΩ) of the coil unit, Q, Qa, Qb, f, L, R, ΔQ1, ΔQ2, and Δd are numerical values without respective units.
The configuration and characteristics of each component of the wireless charging device adopted in the transportation means are as described above. In addition, the wireless charging device adopted in the transportation means has a value of Relationship (1) of 1.1 or more; thus, possible advantageous effects may be applied in the same manner.
The transportation means may further comprise a battery for receiving power from the wireless charging device. The wireless charging device may receive power wirelessly and transmit it to the battery, and the battery may supply power to the driving system of the electric vehicle. The battery may be charged by power transmitted from the wireless charging device or other additional wired charging devices.
In addition, the transportation means may further comprise a signal transmitter for transmitting information about the charging to the transmitter of the wireless charging system. The information about such charging may be charging efficiency such as charging speed, charging state, and the like.
Hereinafter, the embodiments will be described with more specific examples, but the scope of the embodiment is not limited to this scope.
A coil tray was used as a support unit (100), and a coil unit (200) was accommodated and fixed in the groove of the coil tray. Referring to
A magnetic unit (300) was prepared to have a dimension of 320 mm×320 mm×5 mm (width×length×thickness), and the material of the magnetic unit was a sintered ferrite material or a polymer-type magnetic material. First, for the sintered ferrite material, a ferrite slurry was molded into a sheet form and sintered to obtain 16 ferrite units of 80 mm×80 mm×5 mm (width×length×thickness), which were then combined to prepare the magnetic unit of 320 mm×320 mm×5 mm (width×length×thickness). In addition, for the polymer-type magnetic material, a mold capable of forming a shape having a corresponding dimension (320 mm×320 mm×5 mm) was first manufactured, and a magnetic powder slurry was then injected into the mold using an injection molding machine to obtain the magnetic unit.
As a shield unit (400), an aluminum plate having a dimension of 350 mm×350 mm×2 mm (width×length×thickness) was used.
Referring to
A coil tray was used as a support unit (100), and a coil unit (200) was accommodated and fixed in the groove of the coil tray. Referring to
A ferrite slurry was molded into a sheet form and sintered to obtain 16 ferrite units having a thickness of 5 mm, which were then combined to prepare the magnetic unit (300) of 675 mm×534 mm×5 mm (width×length×thickness).
As a shield unit (400), an aluminum plate having a dimension of 675 mm×534 mm×2 mm (width×length×thickness) was used.
In the wireless charging devices (Device A or B) prepared above, referring to
In addition, the values of Relationships (1 ) to (3) were calculated based on these measurement data. The results are shown in Tables 2 to 7.
Calculated value of Relationship (1)=[ΔQ1−ΔQ2)/Q]×100
Calculated value of Relationship (2)=[(ΔR1−ΔR2)/R]×100
Calculated value of Relationship (3)=[(ΔL1−ΔL2)/L]×100
Here,
ΔQ1=(Q−Qa)/Δd,ΔQ2=(Qb−Q)/Δd,
ΔR1=(R−Ra)/Δd,ΔR2=(Rb−R)/Δd,
ΔL1=(L−La)/Δd,ΔL2=(Lb−L)/Δd,
Qa, Ra, and La are each Q, R, and L when the distance between the magnetic unit and the shield unit is further decreased by Δd,
Qb, Rb, and Lb are each Q, R, and L when the distance between the magnetic unit and the shield unit is further increased by Δd, and
Δd=2.0 mm.
As can be seen from the above table, when the distance between the magnetic unit and the shield unit was 4.0 mm to 6.0 mm (sintered ferrite) or 4.5 mm to 6.0 mm (polymer-type magnetic material) in device A, the calculated value of Relationship (1) was 1.1 or more. Meanwhile, when it was outside the above ranges, there was a problem in that the Q factor was low, which deteriorated the resonance characteristics, or the overall thickness of the device increased without an additional enhancement of the Q factor. In particular, the calculated value of Relationship (1) was the highest when the distance between the magnetic unit and the shield unit was 5.0 mm.
As can be seen from the above table, when the distance between the magnetic unit and the shield unit was 4.0 mm to 6.0 mm (sintered ferrite) or 4.0 mm to 6.5 mm (polymer-type magnetic material) in device B, the calculated value of Relationship (1) was 1.1 or more. Meanwhile, when it was outside the above ranges, there was a problem in that the Q factor was low, which deteriorated the resonance characteristics, or the overall thickness of the device increased without an additional enhancement of the Q factor. In particular, the calculated value of Relationship (1) was the highest when the distance between the magnetic unit and the shield unit was 5.0 mm.
As can be seen from the above table, when the distance between the magnetic unit and the shield unit was 4.0 mm to 6.0 mm (sintered ferrite) or 4.5 mm to 6.0 mm (polymer-type magnetic material) in device A, the calculated value of Relationship (2) was −1.1 or less. Meanwhile, when it was outside the above ranges, there was a problem in that the resistance of the coil unit increased, which intensified heat generation during wireless charging, or the overall thickness of the device increased without an additional decrease of the resistance. In particular, the calculated value of Relationship (2) was the lowest when the distance between the magnetic unit and the shield unit was 5.0 mm.
As can be seen from the above table, when the distance between the magnetic unit and the shield unit was 4.0 mm to 6.0 mm (sintered ferrite and polymer-type magnetic material) in device B, the calculated value of Relationship (2) was −1.1 or less. Meanwhile, when it was outside the above ranges, there was a problem in that the resistance of the coil unit increased, which intensified heat generation during wireless charging, or the overall thickness of the device increased without an additional decrease of the resistance. In particular, the calculated value of Relationship (2) was the lowest when the distance between the magnetic unit and the shield unit was 5.0 mm.
As can be seen from the above table, when the distance between the magnetic unit and the shield unit was 2.0 mm to 6.5 mm (sintered ferrite) or 2.0 mm to 5.0 mm (polymer-type magnetic material) in device A, the calculated value of Relationship (3) was 0.1 or more. Meanwhile, when it was outside the above ranges, there was a problem in that the inductance of the coil unit decreased, which deteriorated charging efficiency, or the overall thickness of the device increased without an additional enhancement of the inductance.
As can be seen from the above table, when the distance between the magnetic unit and the shield unit was 4.0 mm to 6.5 mm (sintered ferrite) or 5.0 mm to 6.5 mm (polymer-type magnetic material) in device B, the calculated value of Relationship (3) was 0.1 or more. Meanwhile, when it was outside the above ranges, there was a problem in that the inductance of the coil unit decreased, which deteriorated charging efficiency, or the overall thickness of the device increased without an additional enhancement of the inductance. In particular, the calculated value of Relationship (3) was the highest when the distance between the magnetic unit and the shield unit was 5.0 mm.
The wireless charging device A or B prepared above was used as a receiver for measuring charging efficiency, and the wireless charging device C prepared above was used as a transmitter. While the transmitter voltage was fixed at 380 V and the receiver current was fixed at 20 A, the transmitter current was changed to adjust the transmit power. When the received power of the receiver reached 8.8 kW, the charging efficiency was calculated according to the equation below.
Charging efficiency (%)=(received power (kW)/transmitted power (kW))×100
As a result, the highest charging efficiency (up to 87.7%) was measured when the distance between the magnetic unit and the shield unit was 5.0 mm in both Devices A and B. Meanwhile, when the distance between the magnetic unit and the shield unit was narrower than 5.0 mm, the charging efficiency gradually decreased. On the other hand, when the distance between the magnetic unit and the shield unit was wider than 5.0 mm, no further enhancement in charging efficiency was observed.
| Number | Date | Country | Kind |
|---|---|---|---|
| 10-2020-0171698 | Dec 2020 | KR | national |
| Filing Document | Filing Date | Country | Kind |
|---|---|---|---|
| PCT/KR2021/014403 | 10/15/2021 | WO |
