Vehicle Shear Panel Integrating Secondary Coil for Inductive Charging
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Solution Overview
Problem
The integration of a secondary coil for inductive energy transmission in vehicles, particularly in plug-in hybrid-electric vehicles, faces challenges due to limited space and the need for efficient electromagnetic shielding, especially under the front axle where geometrical and thermal conditions are more difficult, and there is a requirement for high energy transmission efficiency and compliance with legal electromagnetic shielding demands.
Innovation Solution
A shear panel is used in the forward structure of the vehicle, constructed of metal with a receiving area for mechanical fastening of the secondary coil, which also serves as an electromagnetic shielding and impedance adaptation component, utilizing magnetic resonance technology to enable efficient energy transmission and reduce the size and weight of the secondary coil.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If the secondary coil is integrated under the front axle support, then electromagnetic shielding efficiency and energy transmission efficiency are improved, but the available installation space and ease of integration are reduced
Solution Approach 1:
The patent combines the secondary coil assembly with the front axle support structure into an integrated unit. The secondary coil is mounted directly on the front axle support, merging two previously separate components (coil assembly and axle support) into one unified structure, thereby optimizing space utilization while maintaining electromagnetic shielding efficiency
Solution Approach 2:
The front axle support structure serves multiple functions: it provides mechanical support for the wheel assembly, acts as a mounting platform for the secondary coil, and functions as part of the electromagnetic shielding system. This multi-functionality reduces the need for separate dedicated components and maximizes the use of available space
2Weight of moving object
If the secondary coil is made smaller and lighter, then integration simplicity and energy transmission efficiency are improved, but electromagnetic shielding capability and thermal management are worsened
Solution Approach 1:
The patent introduces a non-conductive housing or enclosure as an intermediary component between the lightweight secondary coil and the external environment. This housing provides the necessary electromagnetic shielding and thermal management capabilities, allowing the coil itself to remain small and light while the protective enclosure handles the shielding function
Solution Approach 2:
The patent employs composite material structures for the secondary coil assembly, combining lightweight materials (such as aluminum or composite alloys) with electromagnetic shielding materials (such as conductive coatings or mesh layers). This allows the assembly to maintain reduced weight while incorporating adequate electromagnetic shielding capabilities
3Reliability
If separate electromagnetic shielding measures are implemented, then legal compliance (ICNIRP) is achieved, but device complexity and installation requirements are increased
Solution Approach 1:
The electromagnetic shielding function is merged into the existing vehicle body structure and front axle support components. Rather than adding separate dedicated shielding components, the design utilizes the vehicle's existing metal structures and body panels as part of the shielding system, thereby reducing overall device complexity
Solution Approach 2:
Existing vehicle components such as the front axle support, body panels, and underbody structures are designed to serve dual purposes: their primary mechanical/functions and additional electromagnetic shielding functions. This multi-functionality eliminates the need for separate shielding components and simplifies the overall system
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 shear panel provides precise mechanical integration, efficient electromagnetic shielding, and impedance adaptation, optimizing energy transmission efficiency while reducing the weight and size of the secondary coil, and acts as a heat sink to prevent overheating, enhancing the overall performance and compliance with legal standards.
Implementation Method 1
measures are required for the electromagnetic shielding in order to meet legal demands (ICNIRP)
Implementation Method 2
The energy transmission to the secondary coil takes place inductively by means of a primary coil of the energy transmission system
Implementation Method 3
energy transmission systems which utilize magnetic resonance technology
Implementation Method 4
acts as a heat sink to prevent overheating
Data Source
AI summary
A shear panel for a forward structure of a body of a vehicle includes a receiving area having fastening devices for mechanically fastening a secondary coil of an inductive energy transmission system configured to charge an electric energy accumulator of the vehicle. The shear panel may be made of metal.