PCB Receiver Coil Air-Gap Cooling for Dynamic Wireless Charging
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Solution Overview
Problem
Existing wireless inductive charging systems for electric vehicles face overheating issues due to the use of PCB-based coils, which lack effective cooling mechanisms, particularly during high-power applications.
Innovation Solution
Incorporating a wing-shaped leading edge with air gaps between the PCB windings to create pressure differences that facilitate passive airflow through the receiver coil, providing efficient cooling without additional power consumption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If PCB-based coils are used for wireless power transfer, then the charging system can be integrated into the vehicle structure, but the receiver coil overheats during high-power applications
Solution Approach 1:
The patent applies porous materials by creating air gaps within the PCB receiver coil structure. The PCB is designed with multiple air gaps that allow airflow through the coil windings, effectively cooling the receiver during high-power wireless charging. This porous structure enables heat dissipation while maintaining the integrated PCB-based design.
2Temperature
If cooling mechanisms are added to the receiver coil, then overheating is reduced, but the device complexity increases
Solution Approach 1:
The patent implements self-service by designing the PCB receiver coil with integrated air gaps that enable passive cooling through natural airflow. The cooling mechanism is built into the PCB structure itself, eliminating the need for external fans, pumps, or active cooling systems. The air gaps allow ambient air to flow through the coil windings, providing self-cooling without additional power consumption or complex components.
3Temperature
If air gaps are created between windings for cooling, then heat dissipation improves, but the magnetic field coupling efficiency decreases
Solution Approach 1:
The patent applies local quality by strategically positioning air gaps in specific regions of the PCB receiver coil where heat generation is highest. The air gaps are not uniformly distributed but are placed to optimize both cooling efficiency and magnetic field coupling. This localized approach allows effective heat dissipation in critical areas while maintaining strong magnetic coupling in other regions, balancing thermal management with power transfer efficiency.
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 wing-shaped design with air gaps effectively cools the PCB-based receiver coil, ensuring reliable operation during high-power wireless charging by enhancing airflow and reducing overheating.
Implementation Method 1
create pressure differences that facilitate passive airflow through the receiver coil
Implementation Method 2
transfer power from a magnetic or electromagnetic field, applied in the vicinity of the receiver, to provide electric power
Data Source
AI summary
An apparatus and method of making the apparatus for a wireless device. The wireless device may include a substrate. The wireless device may further include a receiver coil with a plurality of windings around the substrate. The wireless device may further include a plurality of air gaps between at least a portion of the plurality of windings around the substrate, wherein the plurality of air gaps may extend completely through one side of the substrate to an opposite side of the substrate.