Air-Cooled Wireless Charging Layout Using Side Intake Airflow
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Solution Overview
Problem
Existing automotive wireless power transmitters face inefficiencies in cooling due to intake of hot air from unconditioned spaces and require larger packaging to maintain airflow, leading to reduced cooling performance and thermal shutdowns.
Innovation Solution
An air-cooled wireless power transmission system with an inline fan configuration that draws conditioned cabin air from one side of the receiver and exhausts it on the other side, optimizing packaging and cooling efficiency by utilizing both intake and exhaust airflow paths within the system.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If air is intake from spaces below the charger, then cooling airflow is provided to the receiver, but the intake air temperature increases reducing cooling efficiency
Solution Approach 1:
The patent transitions from vertical airflow (intaking air from below the charger) to horizontal airflow (intaking air from the side of the charger). This dimensional change allows the system to draw cooler, climate-controlled cabin air from the side rather than hot air from the unconditioned space below, thereby improving cooling efficiency without increasing system complexity.
2Productivity
If airflow configuration intakes air from climate-controlled cabin, then cooling efficiency is improved, but packaging size increases
Solution Approach 1:
The patent combines the intake cooling path and exhaust cooling path into a single horizontal airflow configuration that passes through the receiver device. By merging the airflow paths and utilizing the receiver's own structure as part of the cooling channel, the system achieves effective cooling with minimized packaging size, avoiding the need for separate, bulky ducting systems.
3Productivity
If larger packaging is used to maintain airflow, then sufficient cooling airflow is generated, but the z-height dimension increases
Solution Approach 1:
The patent replaces vertical airflow paths (which require significant z-height) with horizontal airflow paths that traverse the receiver device laterally. This dimensional shift allows sufficient cooling airflow to be generated without increasing the vertical dimension of the charger, thereby maintaining a compact profile suitable for automotive installations.
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
This design enhances cooling efficiency by using cooler cabin air and reduces thermal shutdowns, while minimizing the vertical height and packaging requirements of the wireless power transmitter.
Implementation Method 1
a radial fan mounted on the wireless charging module to force air through an air duct
Implementation Method 2
a charging coil wirelessly transmits power to a receiver
Data Source
AI summary
A wireless power transmitter includes a charging coil, an electronics housing, and a top side. The charging coil housing houses a charging coil and includes a top surface, wherein the charging coil wirelessly transmits power to a receiver placed on the top surface of the charging coil housing. The electronics housing houses one or more electronics and a fan. The top side is located adjacent to the electronics housing, wherein a top surface of the top side faces a bottom surface of the receiver. An intake cooling path is defined by a region between the bottom surface of the receiver and the top surface of the top side and an exhaust cooling path is located on a side of the charging coil housing opposite the intake cooling path and defined by a region between the receiver and the top surface of the top side.