Inductive Plug Ferrite Core Thermal Management
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Solution Overview
Problem
Existing contactless plug-in devices for inductive energy transmission are limited in their ability to efficiently and safely transmit higher electrical powers, typically in the range of tens of watts to several hundred watts, due to inefficiencies in heat management and mechanical robustness, especially under varying conditions such as vibrations and environmental exposure.
Innovation Solution
The use of ferrite cores to enhance magnetic flux, combined with thermal coupling of electronic components to ferrite cores for efficient heat dissipation, and an operating method that monitors and adjusts energy transmission based on measured operating variables to ensure safe and efficient power transfer, even in the presence of mechanical misalignment or environmental factors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If ferrite cores are used to enhance magnetic flux for higher power transmission, then power transmission capability is improved, but heat generation in electronic components increases
Solution Approach 1:
The patent combines the ferrite core with the housing to create a unified thermal management structure. The housing serves dual functions as both mechanical protection and heat dissipation pathway, while the ferrite core provides both magnetic flux enhancement and thermal conduction to external heat sinks.
Solution Approach 2:
The patent introduces thermal paste as an intermediary substance between electronic components and the housing/ferrite core assembly. This thermal paste optimizes heat transfer from the components to the housing, enabling efficient heat dissipation while maintaining electrical isolation.
2Area of stationary object
If the transmission area is reduced for compact device design, then device size is improved, but magnetic coupling efficiency deteriorates
Solution Approach 1:
The patent uses ferrite core material with high magnetic permeability to concentrate and guide magnetic flux within a compact area. This composite approach combines the coil winding with the ferrite core to achieve high coupling efficiency in a reduced transmission area.
Solution Approach 2:
The patent concentrates magnetic flux density in specific regions by using the ferrite core's high permeability properties. This creates localized areas of enhanced magnetic coupling efficiency, allowing compact design without sacrificing overall transmission reliability.
3Reliability
If monitoring and safety mechanisms are added to ensure safe operation, then operational safety is improved, but device complexity increases
Solution Approach 1:
The patent implements a monitoring system that detects operating variables such as temperature, power transfer efficiency, and coupling status. This feedback mechanism enables real-time safety assessments and automatic adjustment of power transmission parameters to prevent hazardous conditions.
Solution Approach 2:
The patent employs safety mechanisms that automatically detect and respond to abnormal conditions without external intervention. The system self-regulates power transmission based on monitored parameters, eliminating the need for complex external safety systems while maintaining high operational safety.
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 robust and efficient transmission of higher electrical powers with reduced wear and increased safety, allowing for operation in harsh environments and preventing potential hazards by ensuring proper coupling and energy transfer only when suitable conditions are met.
Implementation Method 1
The ferrite core increases the magnetic flux through its permeability in such a way that higher electrical power can be transmitted
Implementation Method 2
contactless plug-in device for inductive energy transmission from a primary part (1) to a secondary part (1')
Implementation Method 3
thermal coupling of electronic components to ferrite cores for efficient heat dissipation
Data Source
Figure 1~2
Figure 3~4
AI summary
A contact-free electrical connector arrangement is provided for transferring inductive energy from a primary connector component to a secondary connector component, comprising a pair of connector components each including a housing containing a chamber, a ferrite core arranged in the chamber, and a coil arranged in the chamber for cooperation with the core. An input cable supplies electrical energy to the coil contained in the housing of a primary one of said components, and an output cable removes inductively-transferred energy from the coil contained in the housing of a secondary one of said components. According to an operating method of the invention, a parameter is measured at the primary coil for interrupting the energy supply when the secondary component is not present.