Coil Unit With Embedded Spiral Cooling Channels
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Solution Overview
Problem
The existing contactless power transmission systems for vehicles face inefficiencies in cooling due to the gap between the coil holder and the cooling layer, leading to increased thickness and reduced handling ease, as well as decreased cooling efficiency.
Innovation Solution
A coil unit design featuring a plate-shaped coil holder with spiral-shaped passages for both the conductor and coolant, allowing for closer proximity and improved thermal conductivity without compromising the strength or thickness of the holder.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If a block-shaped cooling layer is layered on the coil holder, then cooling capacity is provided, but the gap between the cooling layer and coil reduces cooling efficiency
Solution Approach 1:
The invention transitions from a three-dimensional layered structure (cooling layer stacked on coil holder) to a two-dimensional planar structure (cooling channels formed within the coil holder plate). By forming cooling channels inside the coil holder rather than placing a separate cooling layer on top, the gap between the cooling structure and the coil is minimized, significantly improving cooling efficiency while maintaining adequate cooling capacity.
2Ease of operation
If the coil holder thickness is increased to maintain strength and shock resistance, then handling ease is improved, but the gap between coil holder and cooling layer increases reducing cooling efficiency
Solution Approach 1:
The invention merges the cooling function with the coil holder structure by integrating cooling channels directly into the coil holder plate. This integration eliminates the need for a separate cooling layer, allowing the coil holder to maintain its thickness for strength and handling ease while simultaneously providing effective cooling through the embedded channels.
3Temperature
If the volume of the cooling layer is increased to compensate for reduced cooling efficiency, then cooling capacity is maintained, but the overall thickness of the coil unit increases
Solution Approach 1:
The invention embeds the cooling channels within the coil holder plate itself, creating a nested structure where the cooling function is contained inside the structural component. This eliminates the need for an additional external cooling layer, thereby maintaining cooling capacity without increasing the overall thickness of the coil unit.
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 configuration enhances cooling efficiency while maintaining ease of handling and reducing the overall thickness of the coil unit, allowing for effective heat management without increasing the volume of the cooling layer.
Implementation Method 1
the coils need to be cooled... the coil is cooled by layering the coil holder and a block-shape cooling layer
Data Source
AI summary
A coil unit configured to be used in contactless transmission of electric power for running a vehicle includes a coil, and a plate-shaped coil holder that holds the coil. The coil holder has a spiral-shaped first passage and a spiral-shaped second passage. The first passage is formed along a plate surface of the coil holder, and a conductor constituting the coil is disposed in the first passage. The second passage is formed along the first passage and at a position that is different from a position of the first passage in at least a direction extending along the plate surface, and a cooling member is disposed in the second passage.