Wireless Charging Coil Assembly With Thermal Coupling Films
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Solution Overview
Problem
High-power wireless charging systems for electric vehicles face significant thermal challenges due to electromagnetic field emissions, which limit their efficiency and compact design.
Innovation Solution
A three-phase wireless power transfer system with thermally conducting films and aluminum backplates to enhance thermal management, using epoxy or thermal paste to couple ferrite cores and backplates, and incorporating liquid cooling systems where available.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If high-power wireless charging systems are used to provide fast charging, then charging speed and power density are improved, but thermal effects and electromagnetic field emissions increase
Solution Approach 1:
A thermally conducting film is introduced as an intermediary component between the ferrite core and aluminum backplate. This film serves as a thermal mediator that facilitates efficient heat transfer from the ferrite core (which generates thermal effects during high-power operation) to the aluminum backplate (which acts as a heat sink), thereby managing thermal effects while maintaining high-power wireless charging performance
Solution Approach 2:
The patent changes the thermal conductivity parameter of the interface between ferrite core and backplate by introducing a thermally conducting film. This parameter change enables more efficient thermal management, allowing the system to operate at high power levels without excessive temperature rise, thus resolving the contradiction between charging speed and thermal effects
2Power
If high-power wireless charging systems are used, then power density is improved, but device size constraints become more difficult to meet
Solution Approach 1:
The patent merges multiple functions into the backplate structure: it serves as both a mechanical support structure and a thermal management component (heat sink). The aluminum backplate is directly coupled to the ferrite core through the thermally conducting film, combining structural support and thermal dissipation functions into a single integrated component, thereby reducing overall device volume while maintaining high power density
Solution Approach 2:
The aluminum backplate is designed to perform multiple functions simultaneously: providing mechanical support for the coil assembly, serving as a magnetic shield, and acting as a thermal management system. This multi-functionality reduces the need for separate components, enabling compact device design that meets size constraints while delivering high power density
3Temperature
If thermally conducting films are used to couple ferrite core and backplate, then thermal management is improved, but component complexity increases
Solution Approach 1:
The patent uses a thin thermally conducting film instead of a bulky thermal management system. This thin film provides effective thermal coupling between the ferrite core and aluminum backplate while adding minimal complexity to the overall device structure. The flexible nature of the thin film allows it to conform to the components it connects, simplifying integration compared to rigid thermal management systems
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 system effectively mitigates thermal hotspots and maintains component temperatures below threshold limits, enhancing power transfer efficiency and compact design.
Implementation Method 1
a thermally conducting film arranged and configured to thermally couple the ferrite core and the Al backplate
Implementation Method 2
incorporating liquid cooling systems where available
Implementation Method 3
The Al backplate of either the transmitter pad or the receiver pad or both may be configured for liquid cooling
Implementation Method 4
a three-phase wireless power transfer (3φ-WPT) system for wirelessly providing high-frequency AC power
Data Source
AI summary
A receiver construction and/or a transmitter assembly is provided for transfer of wireless power. The receiver and/or transmitter assemblies may include a respective receiver or transmitter coil assembly, a backing, and a core provided between the backing and the respective receiver or transmitter coil assembly. The receiver coil assembly and/or the transmitter coil assembly may include one or more coils provided in an epoxy operable to facilitate thermal transfer from the one or more coils to at least one of the core and the backing. A thermally conductive element may be provided between the backing and the core.