Non-Circular Coil Unit Thermal Conductor Placement
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Solution Overview
Problem
Conventional contactless power transmission coil units with aluminum thermal conductors experience decreased magnetic flux linkage and electromagnetic performance due to heat dissipation issues.
Innovation Solution
A coil unit with a non-circular flat coil and a core member made of a magnetic material, where a thermal conductor with higher thermal conductivity than the core is positioned to face the corner sections of the coil, enhancing heat dissipation while minimizing impact on magnetic flux.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If a thermal conductor is used to dissipate heat from the coil, then heat dissipation performance is improved, but magnetic flux linkage decreases and electromagnetic performance degrades
Solution Approach 1:
The patent applies local quality by differentiating the core member structure into corner sections and non-corner sections. Thermal conductors are selectively disposed only at the corner sections where magnetic flux density is naturally lower, while non-corner sections maintain full ferrite coverage for optimal magnetic flux linkage. This localized differentiation allows heat dissipation functionality to be added without significantly compromising the electromagnetic performance of the entire core.
Solution Approach 2:
The core member is segmented into distinct functional zones: corner sections with thermal conductors for heat dissipation and non-corner sections with ferrite material for magnetic flux linkage. This segmentation allows each zone to perform its specialized function optimally, resolving the contradiction between heat dissipation and electromagnetic performance by spatially separating these competing requirements.
2Reliability
If the entire inter-magnetic-pole core portion is made of ferrite member, then electromagnetic performance is maintained, but heat dissipation performance decreases
Solution Approach 1:
Rather than making the entire core from ferrite material, the patent applies local quality by replacing ferrite with thermal conductor material specifically at the corner sections. This localized material substitution maintains electromagnetic performance in the critical non-corner regions while providing effective heat dissipation pathways at the corners where magnetic flux density is already lower.
Solution Approach 2:
The core member becomes a composite structure combining ferrite material and thermal conductor material in different spatial locations. This composite approach allows the system to simultaneously achieve the electromagnetic properties of ferrite and the thermal conduction properties of metal materials, resolving the trade-off between electromagnetic performance and heat dissipation.
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
Improves heat dissipation performance while maintaining electromagnetic performance by positioning thermal conductors close to the coil, particularly in areas with lower magnetic flux density, thus preventing degradation of inductance and coupling coefficient.
Implementation Method 1
a thermal conductor that has a higher thermal conductivity than the core member... the thermal conductor can be in close proximity to the coil while suppressing the effect on the amount of magnetic flux passing through the core member... the heat of the coil can be introduced to the outside efficiently
Implementation Method 2
a core member made of a magnetic material... suppressing the effect on the amount of magnetic flux passing through the core member
Implementation Method 3
coil unit for contactless power transmission... a non-circular flat coil
Data Source
Figure 1(a)~1(c)
Figure 2
Figure 3(a)~3(c)
AI summary
A coil unit for contactless power transmission includes a non-circular flat coil; a core member made of a magnetic material; and a thermal conductor that has a higher thermal conductivity than the core member. The coil has a corner section and a non-corner section in a coil axial direction view, and the core member and the thermal conductor are disposed to face the non-corner section and the corner section, respectively in a coil axial direction.