Modular Inductive Charging System with Sub-Surface Protection
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Solution Overview
Problem
The challenge is to design an induction charging device for passenger vehicles that offers contact-free energy transfer, electromagnetic compatibility, thermal management, minimal weight, and mechanical protection, while being adaptable to various vehicle models to reduce development costs and enhance integration in limited spaces.
Innovation Solution
The induction charging device incorporates a standardized induction charging module connected to a sub-surface protection and a shield element, with the sub-surface protection made of fiber-plastic composite and the shield element of electrically conductive material for electromagnetic shielding, along with a magnetic field conductor and cooling element for efficient energy transfer and thermal management.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the induction charging device is designed with comprehensive protection and shielding components, then the reliability and electromagnetic compatibility are improved, but the weight and device complexity increase
Solution Approach 1:
The induction charging device is divided into functionally independent modules: a standardized induction charging module and separate vehicle-specific adaptation components (sub-surface protection and shield element). This segmentation allows the heavy protection and shielding components to be optimized separately for each vehicle model while keeping the core charging module standardized and lightweight.
Solution Approach 2:
The standardized induction charging module is designed to be universally applicable across multiple vehicle models. By making this core component model-independent, the patent reduces overall system weight and complexity while maintaining reliable electromagnetic coupling and charging functionality across different applications.
2Adaptability or versatility
If the induction charging device is customized for each vehicle model, then the adaptability and performance are improved, but the device complexity and development costs increase
Solution Approach 1:
The system is segmented into a standardized core module and vehicle-specific adaptation components. The sub-surface protection and shield element are customized per vehicle model to match specific geometric and electromagnetic requirements, while the induction charging module remains standardized, thereby reducing development complexity.
Solution Approach 2:
The patent introduces a flexible adaptation mechanism where the sub-surface protection and shield element can be adjusted or customized for different vehicle models without redesigning the entire charging device. This dynamic approach allows the system to adapt to various vehicle geometries and electromagnetic environments while maintaining a consistent core design.
3Stability of the object's composition
If the induction charging module is positioned closer to the vehicle floor for better integration, then the integration and protection are improved, but the accessibility and installation difficulty increase
Solution Approach 1:
The induction charging device is segmented into a standardized module that can be pre-assembled and tested independently, then installed as a complete unit in the vehicle floor. This segmentation simplifies the installation process despite the low positioning, as the module contains all necessary components (induction coil, electronics, connections) in a self-contained package.
Solution Approach 2:
The standardized induction charging module is designed to be nested within the vehicle floor structure, with the sub-surface protection and shield element forming protective layers around it. This nesting approach allows the module to be positioned close to the floor for optimal electromagnetic coupling while maintaining accessibility during installation through standardized mounting interfaces.
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 a compact, adaptable, and cost-effective induction charging device that protects components from mechanical and electromagnetic influences, ensures efficient energy transfer, and maintains a low weight, thereby simplifying development and production while maximizing charging capacity and reducing thermal losses.
Implementation Method 1
A stationary induction charging station can furthermore be partially buried in the bottom area... generate a time-varying magnetic field via a primary coil... the time-varying magnetic field induces an alternating current or an alternating voltage, respectively, in the induction coil
Implementation Method 2
The shield element, which can be embodied as shield plate, serves the purpose of electromagnetic shielding, because magnetic and electric field emissions are created in response to the energy transfer
Implementation Method 3
The sub-surface protection can be made of a fiber-plastic composite, in the case of which reinforcement fibers are embedded in a plastic matrix, wherein glass fibers can preferably be used as reinforcement fibers, because they are not electrically conductive and are thus electromagnetically neutral
Data Source
AI summary
An induction charging device for an electrically operated vehicle may include a sub-surface protection, a shield element, and an induction charging module. The shield element may include a recess. The sub-surface protection may include a receiving area. The recess and the receiving area may define an insertion area in which the induction charging module is arranged.