Inductive Coil Unit Cavity Design for Mechanical Load Protection
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Solution Overview
Problem
Inductive coil units in electric vehicle charging systems are vulnerable to mechanical loads, which can damage electrical and magnetic components, including sensors and ferrite elements, due to exposure to vehicle wheels and other mechanical stressors.
Innovation Solution
A coil unit design featuring a cover, base, and support element with protrusions forming cavities to distribute mechanical loads, protecting sensors and flux guidance elements from mechanical stress while allowing for a compact and lightweight structure, with sensors and flux guidance elements arranged within these cavities to prevent direct mechanical loading.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a box-shaped housing is used to protect components from mechanical load, then mechanical stability is improved, but device weight and size increase
Solution Approach 1:
The housing is segmented into a base, cover, and support element with cavities. The support element creates cavities between the cover and base, allowing components to be positioned in protected spaces rather than requiring a solid box structure throughout. This segmentation maintains mechanical stability while reducing material usage and weight.
Solution Approach 2:
The patent employs thin-walled cover and base structures that form cavities with the support element. These thin film-like structures provide sufficient mechanical protection for the cavities while being significantly lighter than a solid box housing would require.
2Device complexity
If sensors and ferrite elements are exposed to mechanical load, then device complexity is reduced, but component reliability deteriorates
Solution Approach 1:
The support element acts as an intermediary structure that creates cavities to house sensors and ferrite elements. This intermediary structure protects these components from mechanical loads applied to the cover, allowing them to function reliably without requiring complex protective mechanisms while maintaining structural simplicity.
Solution Approach 2:
The cavity structure is designed beforehand to position sensors and ferrite elements in protected zones. This prior cushioning approach ensures components are shielded from mechanical shocks and loads before they occur, preventing damage without adding complex protective mechanisms.
3Ease of manufacture
If protrusions are formed by fastening separate parts, then manufacturing flexibility is improved, but device complexity increases
Solution Approach 1:
The support element is merged with either the cover or base as an integrated component rather than being a separate fastened part. The protrusions are formed as integral features of this combined structure, reducing the total number of parts and assembly steps while maintaining manufacturing flexibility through standard forming processes.
Solution Approach 2:
The protrusions are formed by changing the geometric parameters of the integrated support element during manufacturing. By adjusting the shape and position of protrusions as design parameters rather than separate components, the structure achieves manufacturing flexibility without increasing part complexity.
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 design effectively protects electrical and magnetic components from mechanical loads, ensuring mechanical stability and reliability of inductive power transmission systems, particularly in high-load scenarios like vehicle charging, while maintaining a compact and lightweight structure.
Implementation Method 1
at least one support element that mechanically supports the cover on the base is arranged between the cover and the base. For this purpose, at least one cavity is formed between the cover and the support element by protrusions on the cover and/or on the support element
Implementation Method 2
a primary coil unit is provided at a charging station which is brought close to a secondary coil unit arranged on the vehicle for charging of the vehicle battery so that the inductive transmission of power is made possible from a primary coil contained in the primary coil unit to a secondary coil contained in the secondary coil unit
Implementation Method 3
ferrite elements that are ordinarily contained in a coil unit for magnetic flux guidance
Data Source
AI summary
In a coil unit of a device for inductive transmission of electrical power with a cover, a base and a coil arranged between the cover and base. During operation of the device, the cover faces another coil unit and the base faces away from it. At least one support element, which mechanically supports the cover on the base, is arranged between the cover and the base. At least one cavity is formed between the cover and the support element by protrusions on the cover and/or on the support element, whereby the cover lies on the support element, and/or at least one cavity is formed between the base and the support element by protrusions on the support element and/or on the base, whereby the support element lies on the base. Sensors or elements for magnetic flux guidance can be arranged protected from mechanical load in such a cavity.