Vehicle Wireless Charger Cooling Channel for Coil and PCB Heat
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Solution Overview
Problem
Conventional wireless chargers for vehicles suffer from insufficient cooling of the printed circuit board (PCB), particularly at the lower end, due to limited air inlet ports and structural design that focuses cooling on specific components, leading to increased costs and noise.
Innovation Solution
A wireless charger design featuring a cooling channel on the coil seating part and auxiliary cooling parts at the coil bracket sides, with air flowing through these channels to directly cool the coil and PCB, and an air guide part in the housing to enhance airflow efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If air inlet ports are limited to a lower side for structure simplicity, then manufacturing ease is improved, but cooling efficiency for lower end portion of PCB deteriorates and noise increases
Solution Approach 1:
The air inlet ports are not limited to the lower side but are also provided on the side surface of the housing, transitioning from a one-dimensional (lower side only) to a two-dimensional (multiple surfaces) configuration. This allows air to be drawn from multiple directions, improving cooling efficiency for the lower end portion of the PCB and reducing noise by distributing the suction load across multiple inlet locations.
2Temperature
If a blowing guide structure is added to direct airflow, then cooling efficiency is improved, but device complexity and cost increase
Solution Approach 1:
The blowing guide structure is merged with the housing itself rather than being a separate component. The housing is designed to incorporate the blowing guide features directly into its structure, eliminating the need for additional standalone blowing guide parts. This integration maintains the cooling efficiency benefits while reducing device complexity and manufacturing cost by consolidating functions into a single component.
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 design intensively cools the coil and PCB, improving charging performance while reducing component count and design complexity, thus lowering costs.
Implementation Method 1
a blower fan which is disposed in a lower portion of the housing and suctions air from below
Implementation Method 2
a cooling channel formed on a seating part on which a coil is seated to flow air, and auxiliary cooling parts formed at both sides of an coil bracket such that the air comes into direct contact with the coil to intensively cool the heated coil
Implementation Method 3
a coil which is seated on an upper surface of the coil bracket and generates a magnetic field when a current flows
Data Source
AI summary
A wireless charger for a vehicle includes a housing, a blower fan disposed in a lower portion of the housing and configured to draw in air from below, a printed circuit board disposed in the housing, a coil bracket disposed above the printed circuit board, and a coil seated on an upper surface of the coil bracket and configured to generate a magnetic field when a current flows. In particular, a cooling channel may be formed in the upper surface of the coil bracket, and air may pass through the cooling channel and cool a lower portion of the coil while the coil is seated.