Wireless Charger Transformer Assembly With Split Cooling Paths
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Solution Overview
Problem
Existing cooling systems for power transformer assemblies in wireless charging systems are not well tailored to the specific heat generation patterns of magnetic and electronic assemblies, leading to manufacturing difficulties and high costs.
Innovation Solution
A power transformer assembly with heat dissipation means arranged between the magnetic and electronic assemblies, comprising different materials and structures for each assembly to address their specific heat dissipation requirements, allowing for modular assembly and reduced manufacturing costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a single cooling system is used for both magnetic and electronic assemblies, then device complexity is reduced, but heat dissipation effectiveness deteriorates due to different heat generation patterns
Solution Approach 1:
The cooling system is divided into two separate parts: a first cooling part for the magnetic assembly and a second cooling part for the electronic assembly. Each cooling part is specifically designed to address the heat dissipation needs of its corresponding heat source, with the first cooling part having a first structure adapted to the magnetic assembly's heat distribution and the second cooling part having a second structure adapted to the electronic assembly's concentrated heat generation points.
Solution Approach 2:
Different cooling structures and materials are applied to different regions based on their specific heat dissipation requirements. The first cooling part uses a structure optimized for the distributed heat pattern of the magnetic assembly, while the second cooling part uses a structure optimized for the concentrated heat points of the electronic assembly, ensuring each region receives appropriate cooling treatment.
2Reliability
If different cooling structures are designed for magnetic and electronic assemblies, then heat dissipation effectiveness is improved, but manufacturing complexity increases
Solution Approach 1:
The first cooling part and second cooling part are integrated into a single heat dissipation means that is arranged between the magnetic assembly and electronic assembly. This integrated design allows both specialized cooling functions to be combined into one manufacturable component or assembly, reducing the number of separate parts while maintaining the tailored cooling structures for each heat source.
Solution Approach 2:
The heat dissipation means serves multiple functions simultaneously: it cools the magnetic assembly through the first cooling part, cools the electronic assembly through the second cooling part, and is positioned between the two assemblies to manage heat from both sources. This multi-functional design consolidates what would otherwise require separate cooling systems into a single universal cooling solution.
3Reliability
If tailored cooling solutions are implemented for each heat source, then heat dissipation effectiveness is improved, but manufacturing cost increases
Solution Approach 1:
By integrating the first cooling part and second cooling part into a single heat dissipation means, the patent reduces the total number of components that need to be manufactured, assembled, and managed. This consolidation maintains the tailored cooling structures for cost-effective production while achieving specialized heat dissipation for each assembly type.
Solution Approach 2:
The unified heat dissipation means performs multiple cooling functions for both magnetic and electronic assemblies, eliminating the need for separate dedicated cooling systems. This multi-functionality reduces overall manufacturing costs by consolidating materials, production processes, and assembly steps while maintaining effective tailored cooling for each heat source.
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 solution provides efficient heat dissipation tailored to each heat source, reducing manufacturing complexity and costs while maintaining mechanical strength and flexibility.
Implementation Method 1
heat dissipation means for dissipating heat generated by the magnetic assembly and by the electronic assembly during their respective power transforming operation
Data Source
AI summary
A wireless charger for charging a high-voltage (HV) battery of a vehicle, comprising a coil configured for wirelessly receiving an oscillating magnetic field from an external transmitter, thereby creating an alternating current (AC), a ferrite arranged adjacent to the coil, cooling channels arranged adjacent to at least one of the ferrite and the coil, the cooling channels configured for providing a flow of coolant, electric components configured for charging the HV battery based on the AC, a metal cover separating the coil and the ferrite from the electric components, at least one of the electric components being arranged adjacent to the metal cover, wherein the wireless charger further comprises an electrically non-conductive part configured for forming the cooling channels at least in part and separating the coil and the ferrite from the metal cover.