Vehicle Coil Unit Structure for Cooling Without Added Weight
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Solution Overview
Problem
Existing contactless electric power transmission systems for vehicles face challenges in maintaining cooling efficiency while preventing weight increase, which is crucial for energy efficiency and mechanical strength.
Innovation Solution
A coil unit design featuring a housing with a heat release member and a support member made of materials with predetermined electrical insulation and thermal conductivity properties, where the support member's width increases towards the inner surface of the housing, optimizing heat transfer and reducing thermal resistance without increasing weight.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If a cooling device is added to improve cooling efficiency, then cooling performance is improved, but weight increases
Solution Approach 1:
The support member itself serves dual functions: providing mechanical support for the coil and acting as a heat release member through its thermally conductive material. This eliminates the need for separate cooling devices, achieving self-service cooling that prevents weight increase while maintaining cooling efficiency
Solution Approach 2:
The support member is designed to perform multiple functions simultaneously: electrical insulation, mechanical support, and thermal conduction. By making the support member universally functional with these three properties, the patent eliminates the need for additional dedicated cooling components, thereby preventing weight increase
2Temperature
If the width of the support member is increased to improve heat transfer, then cooling efficiency is improved, but weight and volume increase
Solution Approach 1:
The support member features variable width with different sections having different dimensions. The width is larger in regions requiring higher heat transfer and smaller in regions where less cooling is needed. This local quality variation optimizes heat transfer efficiency while minimizing the overall weight and volume of the support member
3Temperature
If a support member with high thermal conductivity is used to improve cooling, then heat release is improved, but electrical insulation may be compromised
Solution Approach 1:
The support member is made of a composite material or a material that simultaneously possesses both high thermal conductivity and high electrical insulation properties. This allows the support member to effectively conduct heat away from the coil while maintaining the necessary electrical insulation to prevent short circuits and ensure reliable operation
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 enhances cooling efficiency, ensures desired withstand voltage and heat release properties, and prevents weight and volume increases, effectively addressing the challenge of maintaining energy efficiency and mechanical strength in contactless electric power transmission systems.
Implementation Method 1
a support member that is in contact with the inner surface of the housing and the heat release member and covers at least part of a surface of the coil
Implementation Method 2
a coil that is arranged within the housing and receives AC electric power transmitted in a contactless manner from an electric power transmission apparatus
Data Source
AI summary
A vehicle coil unit includes: a housing; a coil that receives AC electric power transmitted in a contactless manner from an electric power transmission apparatus; and a support member. The housing has a front surface exposed to the outside below a vehicle body. The coil that is arranged within the housing is in direct contact with the housing via a heat release member provided on an inner surface of the housing. The support member is in contact with the inner surface of the housing and the heat release member and covers a surface of the coil. A width of the support member in an orthogonal direction to a protrusion direction of the heat release member changes in an increasing tendency toward the inner surface from a front end side of the heat release member along the protrusion direction.