Inductive Charging Floor Assembly With Coil and Core Cooling
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Solution Overview
Problem
Inductive charging systems for electric vehicles face issues with heat generation in underbody assemblies, leading to increased temperature, reduced charging power, and potential system failure due to excessive heat.
Innovation Solution
A stationary underbody assembly with a housing containing a flat coil and core arrangement, featuring a cooling air duct and supports that actively ventilate to cool the core and coil, using heat-conducting materials to dissipate heat effectively, minimizing electromagnetic interference.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If inductive charging is performed with high charging power, then charging speed is improved, but temperature of the underbody assembly increases excessively
Solution Approach 1:
The underbody assembly is divided into separate functional components: the housing containing the flat coil, the core arrangement with ferrite plates, and the support structure. This segmentation allows independent optimization of each component's thermal management, enabling the coil and core to be cooled separately through the housing walls to the substrate, preventing excessive temperature rise during high-power charging operations
Solution Approach 2:
The patent introduces a third dimension for heat dissipation by extending cooling paths from the coil and core through the housing walls vertically down to the substrate. This dimensional approach to thermal management allows heat to be dissipated in multiple directions simultaneously, enabling high charging power to be maintained without excessive temperature increase in the underbody assembly
2Productivity
If charging power is increased to improve productivity, then charging efficiency is improved, but system reliability deteriorates due to excessive heat
Solution Approach 1:
The housing is designed with integrated thermal conduction paths to the substrate before charging operations begin. The support structure pre-establishes heat dissipation routes from the coil and core through the housing walls to the substrate, ensuring that thermal management capacity is ready in advance. This preliminary thermal pathway establishment prevents temperature-related reliability issues during high-power charging operations
Solution Approach 2:
The housing acts as an intermediary thermal management component, containing the flat coil and core arrangement while providing controlled thermal conduction paths to the substrate. This intermediary structure mediates between the heat-generating charging components and the external environment, enabling high charging power to be maintained while preventing excessive heat accumulation that would compromise system reliability
3Temperature
If the underbody assembly is cooled more effectively, then temperature is reduced, but device complexity increases
Solution Approach 1:
The housing serves multiple functions simultaneously: it contains the flat coil and core arrangement, provides structural support, and acts as a thermal conduction path to the substrate. By merging these functions into a single integrated component, the design achieves effective cooling without adding separate cooling system components, thus avoiding increased device complexity while maintaining reduced temperature during high-power charging operations
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
The solution enables effective cooling of the core and coil components, maintaining rated power under various conditions, reducing the risk of overheating and system failure, and allowing for higher charging power without eddy current losses.
Implementation Method 1
a cooling air duct (16) which can be actively ventilated and thereby cools both the core arrangement (8) and the flat coil (6)
Implementation Method 2
at least one support (15), which is arranged within the central region (10) of an associated core body (9) and connects the core arrangement (8) and the floor (14) in a heat-transferring manner
Implementation Method 3
a flat coil (6), which comprises a conductor (7), is arranged in the housing (12) A core arrangement (8) for guiding a magnetic flux
Data Source
AI summary
A stationary underbody assembly for an inductive charging device for inductive charging of a motor vehicle may include a closed housing, at least one flat coil, a core arrangement configured to guide a magnetic flux, at least one support, and a cooling air duct. The housing may include a floor arranged at a spacing distance from a substrate. The flat coil may be arranged in the housing spaced apart from the floor in a spacing direction. The core arrangement may be disposed in the housing between and spaced apart from the floor and the flat coil. The support may be arranged within a central region of a core body of the core arrangement and connect the core arrangement and the floor in a heat-transferring manner. The cooling air duct may extend below the floor. The support may penetrate the floor and support the housing on the substrate.