Separated Inductive Charging Coil Layout for Heat and Power Transfer

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Solution Overview

Problem

Existing wireless charging systems face challenges in efficiently transferring power over large distances and accommodating diverse device sizes and power requirements, with limitations in thermal management and integration with internet of things (IoT) capabilities.

Innovation Solution

The development of a wireless charger system that incorporates a physically separate coil assembly and drive electronics, utilizing high thermal conductivity materials and modular design, enabling efficient power transfer through a combination of near-field and far-field charging, along with IoT connectivity and advanced sensor integration.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Device complexity

If wireless charging systems use integrated coil and electronics design, then device complexity is reduced, but power transfer efficiency and thermal management capability deteriorate

Engineering Contradiction:

Improveintegration of coil and electronicsVSAvoidpower transfer efficiency

Core Design Contradiction:

Device complexityVSLoss of energy

Solution Approach 1:

The wireless charging system is divided into separate functional modules: the coil assembly is physically separated from the drive electronics and housed in distinct enclosures. This segmentation allows each component to be optimized independently for its specific function while improving overall power transfer efficiency and thermal management.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

A shielded electrical cable acts as an intermediary connection between the separate coil assembly and drive electronics enclosures. This intermediary enables efficient power and signal transmission while allowing physical separation of components for optimized performance and thermal management.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Loss of energy

If charging coil is positioned close to charging surface, then power transfer efficiency improves, but thermal management capability deteriorates

Engineering Contradiction:

Improvepower transfer efficiencyVSAvoidthermal management

Core Design Contradiction:

Loss of energyVSTemperature

Solution Approach 1:

The drive electronics generating heat are extracted from the first enclosure containing the charging coil. This extraction removes the primary heat source from proximity to the coil, enabling independent thermal management of each component while maintaining close positioning for efficient power transfer.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

Each enclosure is designed with location-specific properties: the first enclosure optimizes for electromagnetic field generation and power transfer efficiency, while the second enclosure optimizes for thermal dissipation and electronics protection. This local optimization resolves the contradiction between close positioning and thermal management.

Inventive Principle:

Principle #3Local quality

3Adaptability or versatility

If wireless charger supports multiple device sizes and orientations, then adaptability improves, but alignment precision and power transfer efficiency deteriorate

Engineering Contradiction:

Improvedevice size and orientation supportVSAvoidalignment precision

Core Design Contradiction:

Adaptability or versatilityVSManufacturing precision

Solution Approach 1:

The wireless charging system is designed with universal compatibility features that allow it to charge various device sizes and orientations effectively. The separated coil and electronics design enables flexible configuration to accommodate different device form factors while maintaining alignment precision through optimized electromagnetic field distribution.

Inventive Principle:

Principle #6Universality (Multi-functionality)

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 enhances power transfer efficiency, supports charging of various devices regardless of size and orientation, and integrates IoT features for remote monitoring and control, improving user experience and system flexibility.

Implementation Method 1

The inductive charging coil is configured to transmit electromagnetic power by inductive power transfer through the charging surface of the enclosure with an alternating magnetic field at an operating frequency

Methodology Applied

Scientific EffectElectromagnetic induction: Electromagnetic Induction