Wireless Charging Magnetic Unit Cooling for Sealed EV Systems
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Solution Overview
Problem
Conventional wireless charging devices for electric vehicles generate heat due to coil resistance and magnetic material loss, leading to impedance mismatch and reduced efficiency, which is exacerbated by the sealed structure, making heat dissipation difficult.
Innovation Solution
Incorporating a channel inside or adjacent to the magnetic unit for cooling fluid circulation, such as air or refrigerant, to directly contact and discharge heat generated during wireless charging.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a sealed structure is adopted for dustproofing, waterproofing, and shock absorption, then reliability is improved, but heat dissipation capability deteriorates
Solution Approach 1:
The sealed housing is segmented by introducing cooling channels that divide the internal space into functional zones. The housing structure is split to accommodate fluid passages while maintaining external sealing, allowing heat dissipation pathways to be integrated without compromising the sealed enclosure's protective function.
Solution Approach 2:
A cooling fluid acts as an intermediary substance that absorbs heat from the magnetic material and coil unit within the sealed housing. The fluid circulates through channels, transferring thermal energy from the heat-generating components to external cooling systems, thereby enabling heat dissipation while the housing remains sealed against dust, water, and shocks.
2Productivity
If magnetic material is disposed adjacent to the coil to enhance wireless charging efficiency, then charging efficiency is improved, but heat generation increases
Solution Approach 1:
The magnetic material is strategically positioned in specific zones adjacent to the coil where it enhances charging efficiency most effectively. Cooling channels are concurrently positioned to target the local heat-generating regions, creating a differentiated structure where magnetic enhancement and heat removal are spatially optimized together rather than uniformly applied.
Solution Approach 2:
The heat generated by the magnetic material and coil, which is a harmful byproduct reducing charging efficiency, is converted into a manageable thermal flow. By introducing cooling fluid channels that directly contact these components, the harmful heat is captured and transported away, transforming the waste thermal energy into a controlled cooling process that actually improves overall system efficiency.
3Temperature
If cooling channels are introduced to improve heat dissipation, then temperature control is improved, but device complexity increases
Solution Approach 1:
The cooling channels are merged with the existing housing structure rather than being added as separate external components. The channels are integrated into the housing walls and internal framework, combining the protective housing function with the thermal management function in a single unified structure, thereby reducing overall device complexity despite the added cooling capability.
Solution Approach 2:
The housing structure serves multiple functions simultaneously: it provides mechanical protection against shocks, maintains sealing against dust and water, and now also serves as the framework for cooling channels. This multi-functionality eliminates the need for separate dedicated cooling components, reducing overall system complexity while achieving effective heat dissipation.
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
Enhances heat dissipation and charging efficiency by effectively removing heat from the magnetic unit, maintaining optimal magnetic characteristics and preventing degradation.
Implementation Method 1
a fluid for cooling is introduced into the channel and comes into contact with the magnetic unit
Implementation Method 2
a channel provided inside or adjacent to the magnetic unit, in which a fluid for cooling is introduced
Implementation Method 3
The wireless power transmission refers to wirelessly transmitting power through space using inductive coupling
Implementation Method 4
a magnetic unit disposed between the coil unit and the shield unit
Data Source
AI summary
A wireless charging device according to one implementation embodiment comprises a flow path arranged inside a magnetic unit or at an adjacent portion, and has cooling fluid flowing into the flow path so as to come in contact with the magnetic unit, and thus the heat generated during wireless charging can be readily discharged. Therefore, the wireless charging device can be effectively useful for a moving means such as an electric vehicle that requires high-capacity power transmission between a transmitter and a receiver.