EV Onboard Charger Magnetic Block Potting Fixation
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Solution Overview
Problem
The existing On Board Charger (OBC) designs are prone to damage from vibrations and shocks due to the mechanical fixation of magnetic parts using screws, which also occupy significant space and lack effective heat dissipation and EMC shielding.
Innovation Solution
The magnetic parts (input inductors, transformer, output inductors) are integrated into a single magnetic block within the OBC housing, secured by potting that covers them partially, providing robust fixation, reduced size, EMC shielding, and improved heat dissipation through enhanced contact with the housing acting as a heat sink.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If magnetic parts are fixed using screws, then mechanical fixation is achieved, but sensitivity to vibrations and shocks increases
Solution Approach 1:
The patent merges multiple magnetic parts (input inductor, transformer, output inductor) into a single integrated magnetic block, eliminating the need for separate screw fixations for each component. This consolidation reduces mechanical fixation complexity and improves robustness against vibrations and shocks.
Solution Approach 2:
The patent replaces the mechanical screw fixation system with a potting-based encapsulation system. The magnetic block is embedded in potting material that provides mechanical anchoring and vibration damping, eliminating the need for separate mechanical fasteners and reducing sensitivity to vibrations and shocks.
2Volume of moving object
If magnetic parts are arranged separately in three blocks, then individual component access is maintained, but space consumption increases
Solution Approach 1:
The patent combines three separate magnetic blocks into one integrated magnetic block, significantly reducing the volume occupied by magnetic components in the OBC housing. This consolidation eliminates gaps and redundant structures between separate blocks, optimizing space utilization.
3Reliability
If magnetic parts are covered by potting, then fixation robustness is improved, but heat dissipation capability may be reduced
Solution Approach 1:
The patent applies potting material selectively to provide mechanical support and fixation robustness where needed, while maintaining thermal pathways for heat dissipation. The potting is applied in a manner that does not completely encapsulate heat-generating areas, allowing heat to conduct to the housing for dissipation.
4Object-affected harmful factors
If separate magnetic blocks are used, then individual component replacement is easier, but EMC shielding effectiveness is reduced
Solution Approach 1:
The patent integrates multiple magnetic components into a single magnetic block, creating a unified structure that provides superior EMC shielding. The consolidated block acts as a single electromagnetic shield, reducing interference between components and improving overall electromagnetic compatibility.
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 the robustness and compactness of the OBC, reduces external dimensions, provides effective EMC shielding, and improves heat dissipation, allowing for a simpler and more efficient cooling circuit with lower pressure drop.
Implementation Method 1
the compartment being at least partially filled with potting which at least partially covers the at least one transformer, the at least one input inductor and the at least one output inductor
Implementation Method 2
the contact between the magnetic block comprising all the magnetic parts and the housing of the OBC (which acts as a heat sink) is highly increased to improve heat dissipation
Implementation Method 3
the base of the housing incorporating a cooling circuit
Implementation Method 4
Transformer: is a magnetic part, used for the isolation and for the adaptation of voltages/currents, between the Input side and the Output side
Data Source
AI summary
On board charger for electric vehicles having an AC input and a DC power output and comprising a housing that contains a power electronic circuit, a control electronic circuit, capacitors, inverters, at least one transformer, input inductor and output inductor inside to allow the conversion of input AC power into output DC power, the base of the housing incorporating a cooling circuit, such that the at least one transformer, the at least one input inductor and the at least one output inductor are arranged in a compartment delimited by several side walls and the base of the housing of the on board charger and at least one internal wall, the compartment being at least partially filled with potting which at least partially covers the at least one transformer, the at least one input inductor and the at least one output inductor, these three elements constituting one magnetic block.