Inductive Charging Ground Assembly With Passive Heat-Conducting Support
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Solution Overview
Problem
Existing inductive charging systems for electric vehicles face challenges with mechanical and thermal stresses due to vehicle weight and heat generation, leading to potential failure of components and the need for complex and expensive active cooling solutions.
Innovation Solution
A base assembly design featuring a conductive heat-conducting element that dissipates heat from the core body to the base plate through a thermally conductive sheath, allowing for optimized load transfer and cooling without interfering with the magnetic field, using materials like aluminum and copper for high thermal conductivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If robust and over-dimensioned load-critical components are designed to withstand mechanical and thermal stresses, then reliability is improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The base assembly is segmented into functionally distinct components: the base plate handles mechanical loading and primary heat dissipation, while separate support elements provide thermal conduction paths from the coil to the base plate. This segmentation allows each component to be optimized for its specific function without requiring overall over-dimensioning of the entire structure.
Solution Approach 2:
Thermally conductive support elements act as intermediary components between the coil and the base plate. These supports conduct heat from the coil to the base plate, enabling effective heat transfer without requiring direct contact between the coil and the base plate, thus maintaining structural integrity while managing thermal stresses.
2Temperature
If active cooling systems are implemented to dissipate heat from the ground assembly, then temperature control is improved, but device complexity and cost increase
Solution Approach 1:
The base assembly utilizes passive self-cooling through its structurally necessary components. The base plate and support elements, which are required for mechanical support anyway, also serve as heat conduction paths. This eliminates the need for separate active cooling systems, as the structural components themselves perform the thermal management function.
Solution Approach 2:
The base plate and support elements serve dual functions: providing mechanical support and structural integrity while simultaneously acting as heat conduction paths. This multi-functionality eliminates the need for dedicated cooling components, reducing overall system complexity while maintaining effective temperature control.
3Temperature
If effective heat sinks made of metal are used to cool the ground assembly, then heat dissipation is improved, but electromagnetic interference increases and arrangement becomes complicated
Solution Approach 1:
Thermally conductive materials are strategically positioned only where needed for heat transfer - specifically in the support elements connecting the coil to the base plate and in the base plate itself. This localized use of conductive materials provides effective heat dissipation while minimizing the overall volume of metal in the magnetic field, thereby reducing electromagnetic interference.
4Productivity
If charging power is increased to improve productivity, then charging speed is improved, but heat generation increases leading to component failure
Solution Approach 1:
Heat is actively extracted from the coil and transferred to the base plate through the thermally conductive support elements. By extracting heat from the heat-generating component (the coil) and transferring it to a heat-dissipating component (the base plate), the system can sustain higher charging powers without exceeding temperature limits of critical components.
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
Enables higher charging power with improved mechanical stability and reduced component failure risk, while maintaining a simple and cost-effective design by minimizing electromagnetic interference and providing a flexible installation space for electronic components.
Implementation Method 1
at least one thermally conductive element (14) which connects the core body (11) and the base plate (4) in a heat-transferring manner
Implementation Method 2
a primary coil (7) is located in a ground assembly outside the vehicle, which inductively interacts with a secondary coil (vehicle assembly) inside the vehicle
Data Source
Figure 1~2
Figure 3~4
AI summary
The present invention relates to a base assembly (1) for an inductive charging device (2) for inductively charging a motor vehicle parked on a surface (5), comprising: - a base plate (4), in particular designed as a cooling plate (3), which extends in a plate-like shape transversely to a spacing direction (6); - at least one flat coil (7) having a spirally wound conductor (8) and spaced apart in the spacing direction (6) from the base plate (4); - at least one core body (11) which extends in a plate-like shape transversely to the spacing direction (6); - wherein a lower cavity (12) is formed between the at least one core body (11) and the base plate (4); - wherein at least one support (13) is provided between the at least one core body (11) and the base plate (4), which extends through the lower cavity (12) in the spacing direction (6); - wherein at least one heat-conducting jacket (14) is provided.which connects the core body (11) and the base plate (4) in a heat-transferring manner and surrounds at least one support (13) in a sheath-like manner.