Inductive Charging Ground Assembly With Passive Heat Dissipation
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Solution Overview
Problem
Inductive charging devices for motor vehicles face issues with heat dissipation in the ground assembly, leading to temperature differentials and early derating, especially in high ambient temperatures, which limits charging power and requires costly cooling solutions.
Innovation Solution
A ground assembly design with a base plate, helically wound conductor, core arrangement, and heat conducting supports that facilitate targeted heat dissipation and efficient cooling, allowing for higher charging power without derating, using materials with high thermal conductivity and strategic recesses to manage mechanical loads and magnetic interference.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If conventional cooling solutions are used to manage heat in the ground assembly, then temperature control is improved, but device complexity and cost increase
Solution Approach 1:
The ground assembly utilizes the motor vehicle itself as a heat sink by pressing the ground assembly against the vehicle's undercarriage. The vehicle's mass and thermal capacity provide passive cooling, eliminating the need for active cooling systems. The natural contact pressure during vehicle operation drives heat transfer from the ground assembly to the vehicle.
Solution Approach 2:
The invention converts the previously harmful direct contact between conductor and core body (which caused heat generation) into a beneficial cooling mechanism. By pressing the ground assembly against the motor vehicle, the same contact interface that generated heat now serves as a heat dissipation path, transforming the thermal problem into a solution.
2Productivity
If direct electrical connection is used for charging, then charging efficiency is improved, but manual operation is required
Solution Approach 1:
The invention replaces the mechanical plug-and-socket connection system with an inductive coupling system. Electrical energy is transferred wirelessly through magnetic coupling between the ground assembly and the motor vehicle, eliminating the need for manual connection while maintaining high charging efficiency.
Solution Approach 2:
The ground assembly serves multiple functions: it provides inductive charging through electromagnetic coupling, simultaneously acts as a heat sink for thermal management, and utilizes the vehicle's weight to maintain contact pressure. This multi-functionality achieves efficient charging without manual operation while solving the thermal management problem.
3Productivity
If higher charging power is transmitted, then productivity is improved, but heat generation increases leading to derating
Solution Approach 1:
The invention transforms the heat generation problem into a solution by using the motor vehicle's large thermal mass as a heat sink. The heat that would otherwise cause derating is efficiently transferred to the vehicle, enabling sustained high-power charging without temperature limits.
Solution Approach 2:
The invention changes the thermal parameters of the system by introducing the motor vehicle as a thermal reservoir. This fundamentally alters the heat balance equation, allowing much higher power densities to be sustained by continuously transferring heat to the vehicle's large thermal mass.
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 design enables effective heat dissipation and mechanical support, allowing for higher charging power without derating, even in extreme conditions, while minimizing magnetic interference and maintaining mechanical integrity.
Implementation Method 1
a heat conducting element is provided, which surrounds the pressure pedestal at least partially and connects the stranded wire carrier with the core body in a heat-transmitting manner
Implementation Method 2
a flat coil which is designed as primary coil or field coil, and which possesses a helically wound conductor
Implementation Method 3
a core arrangement for the magnetic flux control, which is spaced apart from the base plate and from the flat coil in the distance direction and arranged between the base plate and the flat coil
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 arrangement, a lower hollow space, a support, and a heat conducting element. The flat coil may be arranged spaced apart from the base plate. The core arrangement may be arranged between and spaced apart from the base plate and a helically wound conductor of the flat coil. The support may be disposed between a core body of the core arrangement and the base plate, and may extend through the lower hollow space. The flat coil may include a stranded wire carrier, which may include a pressure pedestal arranged co-axially to the support. The heat conducting element may at least partially surround the pressure pedestal and may connect the stranded wire carrier with the core body in a heat-transmitting manner.