Ferrite Cold Plate Layout for EV Wireless Charging Heat and EMI
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Inductive wireless charging systems for electric vehicles face issues with heat generation and electromagnetic interference due to high power conversion in traditional rectifiers, leading to inefficiencies and operational challenges.
Innovation Solution
A wireless charging pad design incorporating a ferrite cold plate in thermal contact with the rectifier and receiver coil, along with a heat spreader plate and cooling chambers, to manage heat and electromagnetic interference, utilizing a fluid chamber with fins to direct cooling fluid flow and enhance thermal management.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If the rectifier is spaced apart from the receiver coil, then heat transfer from the rectifier to the receiver coil is minimized, but the device complexity increases and space utilization deteriorates
Solution Approach 1:
A ferrite cold plate is introduced as an intermediary component between the rectifier and the receiver coil. This cold plate serves dual functions: it provides thermal management by conducting heat away from the rectifier through integrated cooling channels, and it acts as an electromagnetic shield to block interference from the receiver coil. This intermediary structure enables the rectifier to be positioned close to the receiver coil without suffering from heat transfer or electromagnetic interference issues.
Solution Approach 2:
The ferrite cold plate performs multiple functions simultaneously: it serves as a heat sink with integrated cooling channels for thermal management, an electromagnetic shield to block interference, and a structural support element. This multi-functionality allows the rectifier to be positioned close to the receiver coil while addressing both heat transfer and electromagnetic interference concerns, thereby reducing device complexity and improving space utilization.
2Object-affected harmful factors
If the rectifier is spaced apart from the receiver coil, then electromagnetic interference from the receiver coil affecting the rectifier is minimized, but the device complexity increases and space utilization deteriorates
Solution Approach 1:
The ferrite cold plate acts as an electromagnetic shield (intermediary) between the receiver coil and the rectifier. Ferrite material is inherently effective at blocking electromagnetic fields, so positioning this cold plate between the coil and rectifier prevents electromagnetic interference from affecting the rectifier's operation, while still allowing the components to be positioned close together for compact design.
Solution Approach 2:
The cold plate utilizes ferrite material, which is a composite ceramic material with specific electromagnetic shielding properties. This material combines magnetic and non-magnetic phases to effectively block electromagnetic fields while maintaining structural integrity and thermal conductivity, enabling the rectifier to operate close to the receiver coil without electromagnetic interference.
3Power
If traditional rectifiers are used for high power conversion, then wireless charging power is improved, but heat generation increases
Solution Approach 1:
The ferrite cold plate serves as a thermal intermediary by providing integrated cooling channels that conduct heat away from the rectifier. This allows the rectifier to handle high power conversion loads without excessive heat accumulation, as the cold plate actively manages the thermal load through fluid circulation in its cooling channels.
Solution Approach 2:
The system changes the thermal parameters of the rectifier environment by introducing active cooling through the ferrite cold plate's fluid circulation system. This allows the rectifier to operate at high power levels by dynamically controlling the cooling fluid flow rate and temperature, thereby managing heat generation while maintaining high power conversion capability.
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 effectively reduces heat transfer and electromagnetic interference, allowing for efficient and reliable wireless charging by maintaining the rectifier and receiver coil in close proximity while preventing overheating and interference, thus improving charging efficiency and safety.
Implementation Method 1
a ferrite cold plate in thermal contact with and sandwiched between the rectifier and the receiver coil
Implementation Method 2
a fluid chamber in fluid communication with the fluid inlet and the fluid outlet
Implementation Method 3
a ferrite cold plate in thermal contact with and sandwiched between the rectifier and the receiver coil
Data Source
AI summary
A wireless charging pad includes a rectifier, a receiver coil, a heat spreader plate sandwich between the rectifier and the receiver coil, and a ferrite cold plate sandwiched between the receiver coil and the heat spreader plate. The ferrite cold plate has a fluid inlet, a fluid outlet, and a fluid chamber in fluid communication with the fluid inlet and the fluid outlet. The fluid chamber includes a primary cooling chamber and a secondary cooling chamber. Primary cooling fins extending from the heat spreader plate are disposed in the primary cooling chamber and secondary cooling fins extending from a base of the ferrite cooling plate are disposed in the secondary cooling chamber. The ferrite cooling plate cools the rectifier and inhibits or blocks electromagnetic leakage from the receiver coil from interfering with operation of rectifier.