Inductive Charging Floor Assembly With Load-Bearing Cooling Plate
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing inductive charging systems for electric vehicles face challenges in mechanical load capacity and heat dissipation, leading to potential overheating and reduced charging power.
Innovation Solution
A floor assembly with a base plate designed as a cooling plate, incorporating a core arrangement with ferrite plates and heat-conducting supports made of materials with high thermal conductivity, positioned transverse to the magnetic field to enhance mechanical load capacity and heat dissipation without compromising magnetic flux density.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the floor assembly is designed to bear the load of the motor vehicle, then mechanical load capacity is improved, but heat dissipation capability deteriorates due to structural constraints
Solution Approach 1:
The base plate is designed to simultaneously fulfill two functions: serving as a structural load-bearing element and acting as a heat dissipation component. The base plate directly supports the motor vehicle load while also functioning as a cooling plate to dissipate heat generated during inductive charging, thereby merging mechanical support and thermal management functions into a single integrated structure.
Solution Approach 2:
The base plate is designed as a multi-functional component that performs both mechanical support and thermal management tasks. It provides structural strength to bear vehicle weight while simultaneously serving as a heat sink and cooling plate to manage thermal loads, eliminating the need for separate structural and thermal management components.
2Power
If charging power is increased, then inductive charging efficiency is improved, but heat generation increases leading to overheating
Solution Approach 1:
The base plate, which would normally just be a passive structural element, is converted into an active heat dissipation device. The same base plate that provides mechanical support is utilized as a cooling plate with integrated cooling channels, transforming the potential harm of heat generation into a beneficial thermal management system that actively cools the charging components.
Solution Approach 2:
The base plate serves itself by performing both structural and thermal management functions without requiring additional dedicated cooling structures. The cooling channels are integrated directly into the base plate, allowing the structure to self-regulate its temperature through passive conduction and active coolant flow, reducing the need for external cooling systems.
3Strength
If support structures are added to increase mechanical load capacity, then strength is improved, but device complexity increases
Solution Approach 1:
The base plate integrates multiple functions that would traditionally require separate components. It combines the structural support function with the heat dissipation function, and also serves as the mounting platform for the coil assembly. This merging of functions reduces the number of separate support structures needed while maintaining or improving overall system strength.
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 allows for higher charging power with improved heat dissipation, reducing the risk of overheating and increasing mechanical load-bearing capacity while maintaining a compact design.
Implementation Method 1
the at least one support is designed as a heat-conducting element made of a material with a thermal conductivity of λ>5 W/(mK) in order to dissipate heat from, for example, the flat coil or the core arrangement via the at least one support to the cooling plate
Implementation Method 2
A primary coil is located in a ground assembly outside the vehicle, which interacts inductively with a secondary coil ('vehicle assembly') in the vehicle to charge the energy storage unit
Data Source
AI summary
A floor assembly for an inductive charging device for inductive charging of a motor vehicle parked on an underground may include a base plate extending transversely to a spacing direction, at least one flat coil disposed spaced apart from the base plate in the spacing direction, a core arrangement for magnetic flux guidance, and at least one support. The flat coil may include a spirally wound conductor. The core arrangement may be disposed spaced apart from the base plate and the flat coil in the spacing direction. The core arrangement may include at least one core body extending transversely to the spacing direction in the form of a plate. A lower cavity may be formed between the core body and the base plate. The support may be arranged between the core body and the base plate, and may extend through the lower cavity in the spacing direction.