Wireless Power Receiver Assembly for Heat and Vibration Resistance
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Solution Overview
Problem
Wireless power reception apparatuses for electric vehicles face challenges in maintaining efficiency and durability due to impact, vibration, water, and dust resistance, as well as heat dissipation issues, leading to reduced power reception rates and service life.
Innovation Solution
A wireless power reception apparatus is manufactured using a thermally conductive polymer molding layer that fills spaces between the coil winding and magnetic tiles, bonding them securely and enhancing heat dissipation, while also incorporating a magnetic field shielding plate to maintain magnetic performance and resist external impacts and vibrations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If a magnetic body is used to absorb the inductive magnetic field and improve transfer efficiency, then power transfer efficiency is improved, but the magnetic body is vulnerable to breaking or damaging due to large impacts
Solution Approach 1:
The patent applies beforehand cushioning by introducing a shock-absorbing structure between the magnetic body and the coil assembly. This structure includes a resilient member that absorbs impact energy before it reaches the magnetic body, preventing breaking or damage while maintaining the magnetic body's function of absorbing the inductive magnetic field and improving power transfer efficiency.
Solution Approach 2:
The patent employs composite materials by combining the magnetic body with a shock-absorbing material in an integrated structure. This composite construction allows the assembly to simultaneously achieve high power transfer efficiency through magnetic field absorption and high reliability through impact resistance, resolving the contradiction between efficiency and durability.
2Loss of energy
If magnetic tiles are arranged at predetermined intervals to maintain magnetic performance, then power reception efficiency is improved, but air gaps between components increase leading to reduced heat dissipation
Solution Approach 1:
The patent applies local quality by providing thermal conductivity enhancement specifically in the regions where air gaps exist between magnetic tiles and the coil assembly. Thermal conductive material is locally applied to these specific areas to improve heat dissipation without requiring changes to the overall magnetic tile arrangement, thus maintaining power reception efficiency while addressing heat dissipation issues.
Solution Approach 2:
The patent introduces thermal conductive material as an intermediary substance between the magnetic tiles and the coil assembly. This intermediary material fills the air gaps and facilitates heat transfer from the coil assembly to the magnetic tiles, resolving the heat dissipation problem caused by air gaps while preserving the predetermined interval arrangement necessary for magnetic performance.
3Reliability
If a complex manufacturing process is used to ensure reliability and performance, then product quality is improved, but manufacturing cost and complexity increase
Solution Approach 1:
The patent merges multiple functions into a single integrated structure. The magnetic tiles serve dual purposes: maintaining magnetic field absorption for power reception efficiency and providing a mounting structure that incorporates shock-absorbing features. The thermal conductive material simultaneously improves heat dissipation and provides additional structural bonding. This merging reduces manufacturing steps and complexity while ensuring reliability and performance.
Solution Approach 2:
The patent applies universality by designing components that perform multiple functions. The magnetic tiles not only absorb the inductive magnetic field but also serve as a structural platform for mounting the coil assembly and providing thermal conduction pathways. This multi-functionality reduces the number of separate components and assembly steps, simplifying manufacturing while maintaining high reliability and performance standards.
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 effectively extends the service life of the wireless power reception apparatus by maintaining magnetic performance and power reception rates, while providing enhanced impact, vibration, water, and dust resistance, and maximizing heat dissipation with a simplified and cost-effective manufacturing process.
Implementation Method 1
forming a thermally conductive polymer molding layer by applying a thermally conductive polymer molding solution to fill spaces between the coil winding and the coupled member of a magnetic tiles-magnetic field shielding plate
Implementation Method 2
a coil winding, which generates magnetically inductive power
Implementation Method 3
forming a magnetic field shielding plate so as to accommodate and fix a plurality of magnetic tiles at predetermined intervals
Data Source
AI summary
A method of manufacturing a wireless power reception apparatus includes: forming a lower tray that includes a thermally conductive material and accommodates and fix a coil winding; arranging a coil winding on the lower tray; forming a magnetic field shielding plate so as to accommodate and fix a plurality of magnetic tiles at predetermined intervals; forming a coupled member of a magnetic tiles-magnetic field shielding plate by arranging the plurality of magnetic tiles at the predetermined intervals on the magnetic field shielding plate; forming a thermally conductive polymer molding layer by applying a thermally conductive polymer molding solution to fill spaces between the coil winding and the coupled member of a magnetic tiles-magnetic field shielding plate and bonding the plurality of magnetic tiles and the coil winding such that the plurality of magnetic tiles are positioned over the coil winding; and curing the thermally conductive polymer molding layer.