Air Cooled Wireless Charging Pad Thermal Management
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Solution Overview
Problem
Wireless charging pads for electric vehicles face challenges in efficiently dissipating heat generated by the magnetics and electronics assemblies, which can impact the reliability and efficiency of power transfer and battery charging.
Innovation Solution
The design incorporates a thermally conductive housing structure with a magnetics assembly housing part and an electronics assembly housing part, where the magnetics assembly is attached to a thermally conductive plastic floor portion and the electronics assembly is attached to a thermally conductive ceiling portion, both acting as thermal paths to dissipate heat into the external environment, along with a potting material that mechanically holds, electrically isolates, and thermally conducts heat away from the components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If the magnetics assembly and electronics assembly are placed close to each other for compact design, then the device complexity is reduced, but heat dissipation becomes inefficient and temperature increases
Solution Approach 1:
The housing is divided into separate magnetics assembly housing part and electronics assembly housing part, allowing independent thermal management for each assembly while maintaining compact overall structure
Solution Approach 2:
A thermal interface material is introduced between the magnetics assembly and the magnetics assembly housing part to enhance heat transfer from the magnetics assembly to the housing structure, which then dissipates heat to the external environment
2Ease of manufacture
If conventional thermal management methods are used, then manufacturing is simpler, but heat buildup between assemblies reduces reliability and efficiency
Solution Approach 1:
The housing structure is designed to serve dual functions: mechanical support for the assemblies and thermal dissipation pathway. The magnetics assembly housing part and electronics assembly housing part act as heat sinks, eliminating the need for separate complex cooling systems while improving reliability through effective heat management
3Temperature
If heat dissipation structures are added to improve thermal management, then temperature control improves, but device complexity and manufacturing difficulty increase
Solution Approach 1:
The housing parts are designed to perform multiple functions simultaneously: providing mechanical support for the assemblies, acting as thermal pathways for heat dissipation, and serving as structural enclosures. This multi-functionality achieves effective thermal management without adding separate dedicated cooling components
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This solution effectively manages heat dissipation, ensuring reliable operation and efficient power transfer by preventing heat buildup between the magnetics and electronics assemblies, thereby enhancing the performance and longevity of the charging pad.
Implementation Method 1
The magnetics assembly is configured to wirelessly receive power from a charging source
Implementation Method 2
the floor portion of the magnetics assembly housing part is a thermal path for the magnetics assembly as heat generated by the magnetics assembly thermally conducts through the floor portion of the magnetics assembly housing part into an external environment of the charging pad
Implementation Method 3
the ceiling portion of the electronics assembly housing part is a thermal path for the electronics assembly as heat generated by the electronics assembly thermally conducts through the ceiling portion of the electronics assembly housing part into an external environment of the charging pad
Implementation Method 4
The potting material mechanically holds the components of the magnetics assembly, electrically isolates the components of the magnetics assembly, and thermally conducts heat generated by the components of the magnetics assembly to the floor portion of the magnetics assembly housing part
Data Source
AI summary
A charging pad includes a housing, an interface layer, a magnetics assembly, and an electronics assembly. The housing has a magnetics assembly housing part and an electronics assembly housing part. The interface layer is within the housing. The magnetics assembly is arranged below the interface layer within the magnetics assembly housing part and the electronics assembly is arranged above the interface layer within the electronics assembly housing part.