Induction Charger Housing Layout for Rain-Resistant Cooling
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Solution Overview
Problem
Conventional stationary induction charging devices for electric vehicles face challenges with cooling efficiency, particularly in scenarios where they are exposed to rainwater or clogged with dirt, leading to inadequate heat dissipation and potential system failure.
Innovation Solution
A design featuring a housing base that forms a heat exchanger with fluid-flowing coolant channels, separated from the installation space and venting space, which uses a liquid-air heat exchanger for efficient heat dissipation, combined with forced convection for cooling components like power electronics and magnetic field conductors, and an electromagnetic shielding housing for protection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If free convection cooling is used through cooling flues in the housing, then the structure is simple and manufacturing is easy, but cooling efficiency is insufficient and the system fails when flooded with rainwater or clogged with dirt
Solution Approach 1:
The housing is divided into a sealed installation space and an unsealed venting space, with the cooling flues positioned in the venting space. This segmentation allows the cooling function to be separated from the protected electronic components, enabling the cooling flues to be exposed to the environment for effective cooling while the electronics remain protected from water and dirt ingress.
Solution Approach 2:
The venting space acts as an intermediary between the sealed installation space and the external environment. It allows air flow through the cooling flues for heat dissipation while preventing direct exposure of the electronics to rainwater and dirt, thus mediating between cooling requirements and protection requirements.
2Temperature
If cooling channels are made open toward the exterior for air or rainwater flow, then cooling capacity increases, but the channels become clogged with dirt and cooling fails
Solution Approach 1:
The housing space is segmented into a sealed installation space containing the electronics and an unsealed venting space containing the open cooling flues. This allows the cooling channels to be open to the exterior for effective heat dissipation while the electronics remain in a protected sealed environment.
Solution Approach 2:
The venting space serves as an intermediary zone that allows direct interaction with the external environment for cooling purposes while protecting the installation space from environmental contaminants. The cooling flues extend into this intermediary space where they can be exposed to air flow without risking clogging of the sealed electronic components.
3Device complexity
If electronics are accommodated in a compartment with cooling flues for free convection, then the structure is simple, but heat dissipation is extremely weak compared to forced convection
Solution Approach 1:
The cooling flues are extended outward from the electronics compartment into a separate venting space, effectively adding a spatial dimension to the cooling path. This allows the cooling surface area to be increased without increasing the complexity of the electronics compartment itself, enabling more effective heat dissipation through extended exposure to ambient air flow.
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, prevents system failure due to water or dirt exposure, and ensures reliable operation by optimizing heat dissipation through a combination of liquid-air heat exchange and forced convection.
Implementation Method 1
The housing base forms a heat exchanger through which liquid can flow for heat exchange from the installation space to the venting space and/or for heat exchange from the installation space to the exterior environment of the stationary induction charging device
Implementation Method 2
The air which is encapsulated in the installation space circulates in a fluid-tight manner, in particular is forced to circulate, for example by means of a fan
Implementation Method 3
heat exchange from the installation space to the exterior environment of the stationary induction charging device
Implementation Method 4
a primary coil and electronics for the supply thereof and/or the controlling of the or each primary coil are accommodated in a shared housing
Data Source
AI summary
A stationary induction charging device for wireless energy transfer may include a housing base, a housing cover, a transmitting coil, at least one magnetic field conductor, and a power electronics unit. The housing base and the housing cover may define an installation space and a venting space. The transmitting coil, the magnetic field conductor, and the power electronics unit may be arranged in the installation space. The housing base may include a plurality of coolant channels through which a liquid is flowable such that the housing base forms a heat exchanger. The plurality of coolant channels may be distributed within the housing base such that a region of the housing base arranged opposite the power electronics unit and/or a region of the housing base arranged opposite the venting space has a higher coolant channel density than a region of the housing base arranged opposite the transmitting coil.