Inductive Charging Base Assembly With Heat-Conducting Coil Support
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Solution Overview
Problem
Inductive charging devices for motor vehicles face challenges with heat dissipation, leading to early derating and reduced charging power due to temperature limitations, especially in adverse climatic conditions, as conventional materials and designs struggle to efficiently manage heat conduction and mechanical loads.
Innovation Solution
The design incorporates a base assembly with a cooling plate, a spirally wound flat coil, and a core arrangement, where heat-conducting supports made of materials with high thermal conductivity connect the coil and core body, allowing efficient heat dissipation and minimizing mechanical stress, while also using thermally conductive particles in plastic to enhance cooling and pressure distribution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If conventional heat dissipation designs are used in the base assembly, then the structure is simple and cost-effective, but the temperature difference between the conductor and base plate becomes excessively large, leading to early derating and reduced charging power
Solution Approach 1:
The base assembly is segmented into multiple functional layers: base plate, heat-conducting support, core body, and flat coil. This segmentation allows each component to perform its specific thermal function optimally, with the support acting as a dedicated heat transfer pathway between the base plate and core body, thereby reducing the overall temperature difference while maintaining structural clarity
Solution Approach 2:
A heat-conducting support serves as an intermediary component between the base plate and the core body. This mediator facilitates efficient heat transfer from the conductor through the core body to the base plate, reducing the temperature difference without requiring direct contact between all components, thus solving the thermal management problem while keeping the structure relatively simple
2Quantity of substance
If the conductor cross-section is reduced to lower costs, then material costs decrease, but the conductor cannot dissipate heat effectively, causing temperature limitations and derating
Solution Approach 1:
The heat dissipation function is extracted from the conductor itself and transferred to the dedicated heat-conducting support and base plate assembly. This allows the conductor to be optimized for electrical performance with reduced cross-section while the thermal management is handled by the support structure with high thermal conductivity materials, separating the electrical and thermal functions
Solution Approach 2:
The heat-conducting support acts as an intermediary that compensates for the reduced heat dissipation capability of the thinner conductor. By providing an additional thermal pathway through the support and base plate, the system maintains effective heat removal even with less conductor material, preserving reliability while reducing material quantity
3Temperature
If high thermal conductivity materials are used for the support, then heat dissipation improves, but the support may become electrically conductive, causing eddy current losses
Solution Approach 1:
The support structure exhibits local quality differentiation: it possesses high thermal conductivity for effective heat dissipation while maintaining electrical insulation properties in the regions where it contacts the base plate and core body. This is achieved by selecting materials and designing the support geometry such that thermal transfer is optimized at contact interfaces while electrical conductivity is minimized in the support body itself, preventing eddy current formation
Solution Approach 2:
The support is made from composite or specialized materials that combine high thermal conductivity with electrical insulation properties. These composite materials enable the support to function as an efficient thermal pathway while blocking electrical current paths, thereby achieving both improved heat dissipation and prevention of eddy current losses simultaneously
4Strength
If the base assembly is designed to bear vehicle weight, then mechanical strength is sufficient, but heat conduction from the conductor to the base plate is impeded by the mechanical load structure
Solution Approach 1:
The mechanical load-bearing function and thermal conduction function are segmented into different components: the base plate and support structure handle mechanical loads, while the heat-conducting support provides a dedicated thermal pathway. This segmentation allows the mechanical structure to be optimized for strength while the thermal structure is optimized for heat conduction, resolving the conflict between load-bearing capacity and heat conduction efficiency
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 solution enables higher charging power with the same conductor cross-section or smaller conductor size, maintains lower temperature differences, and increases mechanical load capacity, reducing the risk of component failure and derating, even in harsh conditions.
Implementation Method 1
a heat-conducting element is provided, which at least partially surrounds the pressure pedestal and connects the stranded wire carrier to the core body in a heat-transferring manner
Implementation Method 2
The at least one support is designed as a heat-conducting element made of a material with a thermal conductivity of λ > 5 W/(m·K)
Implementation Method 3
A primary coil is located in a ground assembly outside the motor vehicle, which inductively interacts with a secondary coil inside the motor vehicle to charge the energy storage device
Data Source
Figure 1~2
Figure 3~4f
Figure 5a~5c
AI summary
The present invention relates to a base assembly (1) for an inductive charging device (2), comprising a base plate (8), a flat coil (5) having a conductor (9), a core arrangement (10) for magnetic flux guidance having at least one core body (11), a lower cavity (14) being formed between the at least one core body (11) and the base plate (8), at least one support (15) being provided between the at least one core body (11) and the base plate (8), at least one support (15) being made of a material with a thermal conductivity of λ > 5 W/(m K), the flat coil (5) having a stranded wire carrier (12) having at least one pressure pedestal (20) on which the stranded wire carrier (12) rests on an associated core body (11), and a heat-conducting element (29) being provided.which at least partially surrounds the pressure platform (20) and connects the strand carrier (12) to the core body (11) in a heat-transferring manner.