Trough-Shaped Base Support for Inductive Vehicle Charging
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Solution Overview
Problem
Inductive charging units for vehicles face high complexity and cost due to the need for multiple components such as shielding plates, spacers, and seals, which increase production costs and complexity.
Innovation Solution
A trough-shaped base support with a convex surface is used, eliminating the need for additional components by incorporating the primary coil and filling material within the trough, which also acts as a mechanical stabilizer and shielding plate, reducing material and weight while maintaining efficient inductive coupling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional components (shielding plates, spacers, seals) are used in inductive charging units, then protection and structural stability are improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The patent combines multiple traditional components (shielding plate, spacers, seals, stabilizing structures) into a single integrated base support structure. The base support has a trough-shaped design with side walls that laterally surround the primary coil, eliminating the need for separate shielding plates and spacers. The filling material in the trough acts as both mechanical support and protection, replacing multiple discrete components.
Solution Approach 2:
The base support structure performs multiple functions simultaneously: it provides mechanical support for the primary coil, acts as a shielding plate for the magnetic field, provides seals to prevent ingress of dust and moisture, and offers stabilizing ground structures. This multi-functional design eliminates the need for separate specialized components for each function.
2Strength
If additional protective components are added to the charging unit, then robustness against mechanical forces is improved, but weight and material cost increase
Solution Approach 1:
The base support integrates stabilizing ground structures and protective elements into its trough-shaped design, eliminating the need for separate supporting columns and protective components. The side walls of the trough provide both structural strength and lateral support, reducing the need for additional stabilizing elements.
Solution Approach 2:
The patent uses a filling material arranged in the trough that surrounds and mechanically fixes the primary coil. This filling material provides mechanical support and protection while being lighter than traditional metal protective structures. The base support itself can be made from punched metal sheet, combining strength with reduced weight.
3Stability of the object's composition
If the base support is made more robust to prevent bending, then structural stability is improved, but manufacturing complexity and cost increase
Solution Approach 1:
The base support features a convex surface directed from the base surface towards the top surface, creating a curved, trough-shaped structure. This curvature provides inherent structural strength and resistance to bending forces while being manufacturable through simple deep-drawing or stamping processes from metal sheets, avoiding complex assembly of multiple rigid components.
4Reliability
If shielding plates are added to protect the magnetic field, then inductive coupling efficiency is improved, but device complexity and cost increase
Solution Approach 1:
The base support's side walls and trough structure serve as the shielding plate for the magnetic field, eliminating the need for separate shielding components. The convex surface and lateral walls of the trough contain and direct the magnetic field generated by the primary coil, ensuring efficient inductive coupling with the secondary coil while integrating the shielding function into the structural support element.
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 design simplifies and cost-reduces the production process, enhances the robustness and safety of the charging unit, and maintains efficient inductive charging by minimizing the shielding of the magnetic field while diverting mechanical forces effectively.
Implementation Method 1
a primary coil (103) for inductive coupling with a secondary coil (203) associated with the vehicle
Data Source
AI summary
An inductive charging unit for a vehicle includes a trough-shaped base support having a base surface and the base surface has laterally enclosing side walls where the base surface and the side walls form a trough. The charging unit further includes a top surface opposite the base surface and a primary coil for inductive coupling to a secondary coil associated with the vehicle, where the primary coil is disposed in the trough. A filling material is disposed in the trough and surrounds the primary coil so as to fix the primary coil mechanically.