Inductive Charging Housing with Plastic-Metal Composite and Segmented Coils
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Solution Overview
Problem
Inductive charging systems for motor vehicles face challenges in efficiently transmitting high energy while ensuring mechanical stability, protecting electrical components, and maintaining adequate cooling, particularly due to the need for robust and durable coil devices that can withstand mechanical damage and varying environmental conditions.
Innovation Solution
The design incorporates a housing with a plastic and metal structure, featuring a ferrite body with overlapping ferrite plates for enhanced magnetic field transmission, a cooling device, and a sensor system for monitoring operating parameters, along with a floating mounting system to accommodate mechanical stress and thermal management, ensuring efficient energy transfer and component protection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If a stationary coil device is used for inductive energy transmission, then electrical energy can be transmitted to the vehicle, but very high currents flow and mechanical damage resistance is compromised
Solution Approach 1:
The coil device is divided into a first coil part and a second coil part arranged adjacent to one another, allowing the mechanical load and electrical current to be distributed across multiple segments, thereby reducing stress on individual components while maintaining high power transmission capability
Solution Approach 2:
The housing combines plastic and metal materials to create a composite structure that provides both mechanical strength for damage resistance and electrical properties for efficient energy transmission, resolving the contradiction between power handling and mechanical durability
2Power
If high power inductive charging is implemented, then energy transmission efficiency improves, but electrical components require special protection and cooling
Solution Approach 1:
The housing integrates multiple functions including mechanical protection, electrical insulation, and thermal management into a single unified structure, allowing high power transmission while maintaining component reliability through combined protective mechanisms
Solution Approach 2:
The housing acts as an intermediary barrier between the high-power electrical components and the external environment, providing electrical isolation and thermal management that protects sensitive components while enabling high power operation
3Length of stationary object
If the housing is made compact with small height, then space requirements are reduced, but mechanical stability and cooling capability are limited
Solution Approach 1:
The coil parts are arranged horizontally adjacent to one another in the width direction rather than stacking vertically, allowing the housing to maintain a compact height while achieving mechanical stability and adequate cooling surface area through extended horizontal dimensions
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
The solution enables reliable, high-energy inductive charging with improved mechanical resilience, effective cooling, and precise energy transmission, while minimizing the risk of damage from mechanical stress and environmental factors.
Implementation Method 1
at least one electrical coil device for inductive energy transmission is arranged... ferrite body with overlapping ferrite plates for enhanced magnetic field transmission
Implementation Method 2
a stationary coil device is usually provided, which interacts with a further coil device provided on the vehicle in order to inductively transmit electrical energy
Implementation Method 3
adequate cooling... cooling device... ensuring efficient energy transfer and component protection
Data Source
Figure 1~3
Figure 4~6
Figure 7~8
AI summary
An electrical assembly (1) for inductive charging current transfer, comprising a housing (2) within which at least one electrical coil assembly (10) for inductive energy transfer is arranged, with an interface that enables electrically conductive contact of this coil assembly (10), wherein the housing (2) has a first housing part (22) and a second housing part (24) which are fastened to one another by at least one fastening means (74), and wherein the two housing parts (22, 24) each extend at least along a longitudinal direction (L) and a lateral direction (B) perpendicular to this longitudinal direction (L), and with at least one electrical connection device (6) for connecting the electrical assembly (1) to a power grid. According to the invention, at least one housing part is made of a plastic.