Inductive Charger Primary Part Cooling Chimneys
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Solution Overview
Problem
Existing inductive charging systems for electric vehicles face challenges in efficient heat dissipation and safety during the charging process, leading to potential overheating and reduced energy transfer efficiency.
Innovation Solution
The primary part of the charging device incorporates a housing element with a primary coil, cooling air channels, and chimneys that facilitate air flow for heat dissipation, featuring a design with beveled sides and a central chimney for improved mechanical stability and surface area for heat exchange, along with optional fans and a lift mechanism for the primary coil to enhance cooling and positioning.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If a movable secondary coil with actuator is arranged in the electric vehicle to minimize air gap during charging, then energy transmission efficiency is improved, but vehicle weight increases and usable space decreases
Solution Approach 1:
Instead of making the secondary coil movable in the vehicle, the patent makes the primary coil movable on the charging station side. The primary coil can be lowered to minimize the air gap with the stationary secondary coil in the vehicle, achieving efficient energy transmission without adding weight or complexity to the vehicle.
Solution Approach 2:
The patent introduces vertical movement capability to the primary coil through a lifting mechanism, allowing it to adjust its position in the z-direction (height) to optimize the air gap distance to the secondary coil, thereby improving coupling efficiency without affecting vehicle design.
2Reliability
If the primary coil is arranged in a closed housing to protect components, then mechanical protection is improved, but heat dissipation deteriorates
Solution Approach 1:
The housing is designed with differentiated local properties: most of the housing remains closed for protection, but specific regions (side walls and top surface) incorporate ventilation openings and heat dissipation structures that allow thermal energy to escape while maintaining overall mechanical protection.
Solution Approach 2:
The patent converts the harmful heat generated by the primary coil into a manageable thermal flow by designing ventilation channels and heat dissipation structures that guide the hot air away from sensitive components, transforming the heat problem into a controlled thermal management system.
3Temperature
If ventilation openings are provided in the housing to improve heat dissipation, then temperature control is improved, but mechanical protection and safety deteriorate
Solution Approach 1:
The housing design incorporates ventilation openings and heat dissipation structures from the outset, before operational issues arise. This preliminary integration of cooling features ensures that heat management is built into the structure itself, eliminating the need for separate protective measures that would compromise cooling efficiency.
Solution Approach 2:
The ventilation and heat dissipation structures are nested within the housing structure itself, with cooling channels and openings integrated into the walls and surfaces. This nested design provides both protection and cooling without requiring additional external 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 design effectively dissipates heat generated during the charging process, ensuring the safety and efficiency of the inductive energy transfer by maintaining optimal operating temperatures and improving the range and usability of electric vehicles.
Implementation Method 1
Devices for the inductive transmission of electrical energy from a primary coil to a secondary coil
Implementation Method 2
at least one channel for cooling air starts from an inlet opening in the area near the floor of a side surface or peripheral surface of the base plate of the primary part and has at least one rising section
Data Source
Figure 1~2
Figure 3~5
Figure 6
AI summary
The invention relates to a primary part of a charger, in particular for the inductive transfer of energy from a primary coil (2) of the primary part (1) to a secondary coil of an at least partially electrically powered vehicle. The primary coil (2) is connected to charging electronics (3) and is arranged on a top surface (7) of the primary part (1). The invention aims to improve the charging process by means of inductive energy transfer from a primary coil (2) to the secondary coil and to increase safety during the charging process. According to the invention, the primary part (1) is provided with at least one chimney (11) extending from bottom to top through the primary part (1), into which at least one channel (10) opens. The inlet opening (8) of this channel is located in the lower region of a side surface of the base plate (18) of the primary part (1), and the channel rises at least in a partial section up to its opening into the at least one chimney (11).