Coolant Manifold Bus Bar for EV Wireless Charging Heat Management

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Solution Overview

Problem

Wireless high current transmission systems for electric vehicle charging generate heat, and existing cooling systems are inefficient in limited vehicle spaces, necessitating a more effective cooling solution.

Innovation Solution

A coolant manifold assembly that circulates coolant between a manifold body and a charging module, incorporating a bus bar to transmit power to a battery while removing heat from the charging module, including a coolant delivering channel and a receiving channel, and a cooler to dissipate heat.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If wireless high current transmission systems are used for charging electric vehicles, then charging efficiency is improved, but heat generation increases

Engineering Contradiction:

Improvecharging efficiencyVSAvoidheat generation

Core Design Contradiction:

ProductivityVSTemperature

Solution Approach 1:

The patent integrates the bus bar (power transmission component) and coolant manifold (cooling component) into a single unified structure. The bus bar serves dual functions: transmitting electrical power to the battery and serving as a heat dissipation pathway by conducting heat away from the charging module to the coolant. This converts the harmful heat generation into a beneficial dual-function component that simultaneously transmits power and manages thermal load.

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

Solution Approach 2:

The patent merges the power transmission function and cooling function into a single integrated assembly. The bus bar and coolant manifold are combined such that the same structural element performs both electrical power delivery and thermal management, reducing component count and improving space utilization in the limited vehicle charging space.

Inventive Principle:

Principle #5Merging (Combining)

2Volume of moving object

If limited space in electric vehicles is considered, then compactness is improved, but cooling efficiency deteriorates

Engineering Contradiction:

Improvespace utilizationVSAvoidcooling efficiency

Core Design Contradiction:

Volume of moving objectVSReliability

Solution Approach 1:

The bus bar and coolant manifold are merged into a single integrated component that performs both power transmission and cooling functions. This consolidation eliminates the need for separate power delivery and cooling systems, significantly reducing the overall volume required for the charging system while maintaining both functions' effectiveness in the limited vehicle space.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The integrated bus bar-coolant manifold assembly serves multiple functions simultaneously: electrical power transmission, heat conduction from the charging module, and coolant flow path provision. This multi-functionality allows the system to maintain effective cooling performance while occupying minimal space within the electric vehicle.

Inventive Principle:

Principle #6Universality (Multi-functionality)

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 provides efficient heat removal from wireless charging modules, enhancing charging efficiency and compactness in limited vehicle spaces by utilizing a coolant manifold assembly that integrates power transmission and cooling, thereby improving the overall performance of electric vehicle charging systems.

Implementation Method 1

a coolant manifold assembly that circulates coolant between a manifold body and a charging module... to remove heat from the charging module

Methodology Applied

Scientific EffectHeat transfer: Conduction (thermal)

Implementation Method 2

a coolant delivering channel delivering coolant to the charging module fluidly communicating with the coolant delivering channel, and a coolant receiving channel receiving the coolant from the charging module

Methodology Applied

Scientific EffectConvection: Convection

Implementation Method 3

a bus bar disposed on the manifold body, the bus bar transmitting power received from the charging module to a battery

Methodology Applied

Scientific EffectElectrical conduction: Conduction (electrical)

Implementation Method 4

a shield layer disposed between the rectifier and the power receiver and magnetically shielding the rectifier from the power receiver

Methodology Applied

Scientific EffectMagnetic shielding: Magnetic Field

Data Source

PatentUS20230395897A1Cooling manifold assemblies, charging modules, and charging systems

Publication Date: 2023.12.07 TOYOTA JIDOSHA KK

AI summary

A coolant manifold assembly is provided. The coolant manifold assembly may include a manifold body having a coolant delivering channel delivering coolant to a charging module fluidly communicating with the coolant delivering channel, and a coolant receiving channel receiving the coolant from the charging module fluidly communicating with the coolant receiving channel. The coolant manifold further include a bus bar disposed on the manifold body, the bus bar transmits power received from the charging module to a battery.