Wireless Transmitter Head Housing with Integrated Rectifier
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Solution Overview
Problem
Existing contactless energy transmission systems are not compact enough and face inefficiencies in heat dissipation and electromagnetic compatibility, particularly in devices with secondary windings and rectifiers.
Innovation Solution
A compact system with a housing containing both the secondary winding and rectifier, utilizing a synchronous rectifier with half-bridges of controllable semiconductor switches and a capacitance, and a metallic housing for improved heat dissipation and electromagnetic shielding, allowing for efficient inductive energy transfer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the secondary winding and rectifier are housed separately, then each component can be optimized independently, but the overall device size increases and heat dissipation becomes less efficient
Solution Approach 1:
The patent combines the secondary winding and rectifier into a single integrated housing structure. The housing contains both components in close proximity, allowing shared thermal management and reducing overall device volume. The metallic housing serves as a common heat sink for both the winding and rectifier, improving heat dissipation efficiency while maintaining compact dimensions.
2Loss of energy
If conventional rectifiers are used, then the design is simpler, but heat generation increases and efficiency decreases
Solution Approach 1:
The patent employs a synchronous rectifier design that actively controls the switching timing and duty cycle of the rectifier elements. By dynamically adjusting these parameters based on the input voltage and load conditions, the rectifier achieves higher efficiency and reduced heat generation compared to conventional fixed-parameter rectifiers, while the control circuit manages the increased design complexity.
3Temperature
If the housing is made of non-metallic material, then electromagnetic interference is reduced, but heat dissipation capability decreases
Solution Approach 1:
The patent utilizes a metallic housing material that provides superior heat dissipation capabilities through its high thermal conductivity. The housing serves as both a structural enclosure and an active heat sink, conducting heat away from the secondary winding and rectifier elements. The metallic construction is designed with appropriate geometries and thermal pathways to maintain electromagnetic compatibility while maximizing thermal performance.
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 system achieves reduced heat loss, improved electromagnetic compatibility, and efficient energy transfer in a compact arrangement, suitable for applications like vehicle power supply without physical contact.
Implementation Method 1
the secondary winding is inductively coupled to the primary conductor and a medium-frequency alternating current can be impressed into the primary conductor, allowing energy to be transferred contactlessly, particularly inductively, from the primary conductor to the secondary winding
Implementation Method 2
The thermal resistance from the secondary winding or rectifier via the housing to the environment, particularly via the potting compound and the housing to the environment, is lower than on any other heat conduction path
Implementation Method 3
the rectifier is a synchronous rectifier. This means it is an 'active rectifier' in which the rectifier's semiconductor switches are not synchronized with the switching signals from the power supply, but rather the voltage drop across the semiconductor switches is measured and they are switched accordingly
Implementation Method 4
the housing has a recess through which a ferrite core, at least partially wrapped by the secondary winding, protrudes
Data Source
Figure 1
AI summary
The invention relates to an electronic device, in particular a transmitter head, and to a system for wireless energy transfer, wherein the device comprises a housing having a secondary winding and a rectifier, in particular wherein the secondary winding feeds the rectifier, wherein power from the secondary winding is supplied to the rectifier, in particular, said rectifier is electrically connected to the secondary winding.