Inductive Charging Ground Assembly With Heat-Conducting Jacket
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Solution Overview
Problem
Existing ground assemblies for inductive vehicle charging face challenges with heat dissipation and mechanical loading, leading to potential overheating and increased complexity and cost due to the need for over-dimensioned components or active cooling, which can interfere with magnetic fields and complicate installation.
Innovation Solution
A ground assembly design featuring a base plate with a heat-conducting core body supported by a heat-dissipating element, where a heat-conducting jacket connects the core body to the base plate, allowing for efficient heat dissipation without interfering with the magnetic field, and incorporating a flat coil and ferrite core for optimized power transmission.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If active cooling with metal heat sinks is used, then heat dissipation is improved, but magnetic field interference increases and device complexity increases
Solution Approach 1:
The patent employs a thin plastic film as a thermal management component that dissipates heat without interfering with the magnetic field, replacing traditional metal heat sinks. This thin film approach provides effective cooling while maintaining electromagnetic compatibility and simplifying the overall device structure.
Solution Approach 2:
The invention changes the material parameter from metal to plastic for the thermal management component. This parameter change allows the heat dissipation structure to be non-magnetic, eliminating field interference while maintaining thermal conductivity sufficient for cooling purposes.
2Strength
If load-critical components are over-dimensioned, then mechanical strength is improved, but device complexity and cost increase
Solution Approach 1:
The patent uses a thin plastic film that provides sufficient mechanical support and load-bearing capacity without requiring over-dimensioning. The film's flexibility and distributed stress characteristics allow it to handle mechanical loads effectively while maintaining a simple, lightweight structure.
3Productivity
If charging power is increased, then productivity is improved, but heat generation increases leading to temperature rise
Solution Approach 1:
The thin plastic film provides an efficient thermal management solution that enables higher charging powers by effectively dissipating the increased heat generation. The film's large surface area to volume ratio enhances heat dissipation capacity, allowing the system to operate at higher power levels without excessive temperature rise.
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 design enhances heat dissipation and mechanical loading capacity, enabling higher charging power with reduced conductor cross-section, simplifies the assembly, and maintains cost-effectiveness while minimizing magnetic field interference.
Implementation Method 1
a conducting heat-conducting element is provided, via which a heat dissipation to the base plate formed in particular as cooling plate and thus a cooling of for example a flat coil
Implementation Method 2
a heat-conducting element formed as a heat-conducting jacket is at least provided, wherein the heat-conducting jacket connects the core body and the base plate in a heat-transmitting manner
Implementation Method 3
a primary coil is located for this purpose which inductively interacts with a secondary coil in the motor vehicle
Data Source
AI summary
A ground assembly for an inductive charging device for inductively charging a motor vehicle parked on a surface may include a base plate, a flat coil, a core body, a lower hollow space, a support, and a heat-conducting jacket. The base plate may be formed as a cooling plate. The flat coil may include a helically wound conductor. The flat coil may be arranged spaced apart from the base plate. The lower hollow space may be defined between the core body and the base plate. The support may be disposed between the core body and the base plate, and may extend through the lower hollow space. The heat-conducting jacket may connect the core body and the base plate in a heat-transmitting manner, and may surround the at least one support in a jacket-like manner.