Lear Corporation

Steven Cong

David Anthony Hein

Ajmal Imran Ansari

Eric Salem

Ryan Cleveland

Allen Leo Mott

Matthew Zamieski

Arthur Hurlburt

Anthony Armento

An induction coil is described for wireless charging of a vehicle battery. The induction coil includes a first electrically conductive strip, a second electrically conductive strip, and a first electrically insulative strip between the first and second electrically conductive strips. The first electrically insulative strip electrically isolates the first electrically conductive strip from the second electrically conductive strip. The first electrically conductive strip, the first electrically insulative strip, and the second electrically conductive strip are integrated into stack, where the stack is configured as multiple windings. The first and second electrically conductive strips are adapted to conduct an alternating current. Alternating current flow through the first and second electrically conductive strips and the plurality of windings generates a magnetic field for wireless inductive charging of the vehicle battery.

Strip induction coil for wireless charging of a vehicle battery

An electric current sensor for detecting a leakage current from an electric vehicle charger. The current sensor includes a magnetic core having a gap formed therein, a first conductor wound around the magnetic core to form a first coil, a second conductor wound around the magnetic core to form a second coil, and a tunnel-magnetoresistance (TMR) sensor element arranged in the gap of the magnetic core. A difference between electric current flow in the first and second conductors produces a magnetic field in the gap of the magnetic core proportional to a leakage current, and the magnetic field produces a voltage in the TMR sensor element indicative of a value of the leakage current.

Electric current sensor for detecting leakage current

A wireless charging unit for an electric vehicle is provided with a metal enclosure to shield a high-power switching noise environment enclosed within the unit. A wireless power transfer system includes the wireless charging unit on the electric vehicle side that receives power wirelessly from a charging base. In addition to a high-power switching network, the wireless charging unit may include a wireless communication system for wirelessly communicating control messages to the charging base. The metal enclosure may include a cutout region having a plastic cover underneath which an antenna may be mounted to establish wireless communication with the charging base from within the metal enclosure.

Wireless charging unit for an electric vehicle

A wireless charger output protection system and method is provided for protecting a battery in an electric vehicle during wireless charging. A wireless power transfer system includes a wireless charger on the electric vehicle side that receives power wirelessly from a charging base. The wireless charger output protection system and method shuts down the wireless charger output and dumps energy in a receive antenna (e.g., a vehicle pad) when a charging error is detected before the charging base can be shut down. The system and method employs a zero-voltage switching (ZVS) scheme to shut down the wireless charger output, in response to the charging error, to protect the switching devices and enhance overall reliability.

System and method of electric vehicle wireless charger output protection using zero voltage switching

A wireless charger output protection system and method is provided for protecting a battery in an electric vehicle during wireless charging from both a desired power source and a stray power source. A wireless power transfer system includes a wireless charger on the electric vehicle side that receives power wirelessly from a charging base. The wireless charger output protection system and method shuts down the wireless charger output and dumps energy in a receive antenna (e.g., a vehicle pad) when a low-voltage battery connected to the wireless charger is lost. The wireless charger output protection system and method also shuts down the wireless charger output and dumps unwanted energy in the receive antenna (e.g., a vehicle pad) when power is transferred from a stray power source coupled to the receive antenna.

System and method for electric vehicle wireless charger output protection

An assembly includes a metallic housing, an electromagnetic (EM) device, and a bobbin in which the EM device is supported. The bobbin has a non-metallic, inner bobbin body, a non-metallic, outer bobbin body, and a metallic shield sandwiched between the inner and outer bobbin bodies. The EM device and the bobbin are mounted in the housing with the bobbin being between the EM device and the housing for heat from the EM device to thermally conduct through the inner and outer bobbin bodies and the shield to the housing while the shield shields noise of the EM device from the housing.

Growing community of inventors

Novi, MI, United States of America

Steven Cong