Wireless Charging Magnetic Unit Composition for High-Temperature Stability
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Solution Overview
Problem
Wireless charging devices for electric vehicles face challenges with thermal resistance and magnetic characteristics, particularly at high temperatures, leading to potential damage and reduced efficiency due to heat generation during charging.
Innovation Solution
A wireless charging device with a magnetic unit designed to have a displacement of 0.07 or less at 180°C, utilizing a polymer-type magnetic unit with specific filler and binder resin compositions, and a coil unit with optimized dimensions and materials to enhance thermal resistance and magnetic characteristics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If wireless charging operation is performed using conventional magnetic units, then power transmission function is achieved, but high-temperature heat generation causes magnetic characteristic changes and device damage
Solution Approach 1:
The patent changes the material parameters of the magnetic unit by selecting specific materials with high Curie temperatures and appropriate magnetic properties. The magnetic unit uses a composite structure with ferrite particles dispersed in a polymer matrix, where the ferrite provides high-temperature magnetic stability and the polymer provides thermal insulation, thereby maintaining magnetic characteristics at elevated temperatures during wireless charging operation
Solution Approach 2:
The magnetic unit is constructed as a composite material system combining ferrite particles (providing magnetic properties and high-temperature stability) with a polymer binder (providing structural integrity and thermal management). This composite structure enables the magnetic unit to withstand high temperatures while maintaining its magnetic characteristics and preventing device damage
2Stability of the object's composition
If magnetic unit material is optimized for high-temperature stability, then thermal resistance is improved, but manufacturing complexity increases
Solution Approach 1:
The magnetic unit employs local quality optimization by concentrating ferrite particles in specific regions where magnetic flux density is highest, while using polymer material in regions requiring flexibility and thermal management. This localized material distribution achieves high-temperature stability where needed while maintaining ease of manufacturing through a modular composite structure that can be produced using conventional molding techniques
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 improved high-temperature stability and charging efficiency, preventing deformation and damage to the magnetic unit, thus ensuring reliable power transmission for electric vehicles and other personal transportation means.
Implementation Method 1
the magnetic unit has a displacement (ΔDR1) at 180° C. represented by the following Equation 1 of 0.07 or less: ΔDR1=(D180-D25)/Ms×100 where D25 is the amount of displacement at 25° C. measured by dynamic mechanical analysis (DMA), and D180 is the amount of displacement at 180° C. measured by dynamic mechanical analysis (DMA)
Implementation Method 2
A wireless charging device generates heat due to the resistance of a coil unit and the magnetic loss of a magnetic unit during the wireless charging operation
Implementation Method 3
A wireless charging device generates heat due to the resistance of a coil unit and the magnetic loss of a magnetic unit during the wireless charging operation
Implementation Method 4
The wireless power transmission refers to wirelessly transmitting power through space using inductive coupling, capacitive coupling, or an electromagnetic field resonance structure such as an antenna without physical contact between a transmitter that supplies power and a receiver that receives power
Data Source
AI summary
A wireless charging apparatus according to an embodiment includes a magnetic unit with a low strain rate (thermal strain) at 180° C., wherein a position change (ΔDR1) at 180° C. is 0.07 or less, to thereby provide the magnetic unit with improved heat resistance and magnetic properties and prevent deformation and damage of the magnetic unit during wireless charging, and further improve the high temperature stability and charging efficiency. Therefore, the wireless charging apparatus can be efficiently used in personal transportation means such as electric motorcycles, electric kickboards, electric scooters, electric wheelchairs, and electric bicycles, as well as transportation means such as electric vehicles requiring large-capacity power transmission between a transmitter and a receiver.