Vehicle-mounted power battery wireless charger and installation method

Abstract

The application discloses a kind of vehicle-mounted power battery wireless charger and installation method, including steps: dispensing on coil disc, form multiple straight lines of glue strip passing through coil disc center position, and the included angle between each pair of adjacent glue strip is same;Wire harness is pressed into the winding groove of coil disc to form coil, coil is fixed by pressing plate tool, and pressing plate tool is removed after fixing preset time;Quantitative glue is filled in the mounting surface of coil disc, after filling glue, place magnetic core, then install fixed support;Vacuum extraction makes the glue filled into gap, solidifies glue.The application is coated with multiple glue strips on the mounting surface of coil disc, each section of glue strip passes through the center of coil disc, the included angle between every two sections of glue strip is same, so that the corner of coil that is easy to be raised can be well fixed, and the glue strips are uniformly spaced, which can save the amount of dispensing, and also can make the coil be fixed uniformly.Meanwhile, the height difference and spacing of magnetic core can be controlled within a reasonable range during the glue filling process after fixing the coil.

Description

Technical Field

[0001] This invention relates to the field of electric vehicle technology, and in particular to a wireless charger for vehicle-mounted power batteries and its installation method. Background Technology

[0002] Currently, electric vehicle battery packs primarily rely on charging stations and are charged via wired connections. However, the convenience and versatility of wired charging are somewhat limited. Therefore, existing electric vehicles can also utilize wireless charging systems. The main characteristics of in-vehicle wireless chargers are high power, compact structure, and high requirements for heat dissipation. Therefore, their manufacturing methods differ significantly from traditional coil systems. However, in existing in-vehicle wireless chargers, the coil is not evenly fixed, and the overall structure is not compact, making it difficult to control the installation position of the magnetic core. Summary of the Invention

[0003] In order to solve the technical problems in the prior art, the present invention proposes a wireless charger for vehicle power batteries and an installation method thereof.

[0004] The technical solution adopted in this invention is:

[0005] This invention proposes a wireless charger for vehicle-mounted power batteries, comprising:

[0006] A coil disk, wherein the mounting surface of the coil disk is provided with a winding groove surrounding the center of the coil disk;

[0007] Multiple adhesive strips are applied to the mounting surface of the coil disc, each strip passing through the center of the coil disc, and the included angle between each pair of adjacent strips is the same.

[0008] The coil is installed in the winding groove and fixed to the coil disc by adhesive strips;

[0009] Multiple magnetic cores are mounted on the mounting surface of the coil disk and cover the coil;

[0010] A fixed bracket is pressed onto the magnetic core.

[0011] Furthermore, an adhesive layer is provided between the coil and the magnetic core, and the adhesive layer penetrates into the gaps between the magnetic cores and the gaps between the coil and the coil disc.

[0012] Furthermore, the path enclosed by the winding groove is a square spiral, with rounded corners at the square bends. The coil is formed by winding a single wire bundle along the winding groove, resulting in a coil composed of alternating straight segments and arc-shaped corner segments.

[0013] Preferably, four adhesive strips are applied in a star-shaped pattern to the mounting surface of the coil disc, with two inclined adhesive strips passing perpendicularly through the arc-shaped corner section of the coil.

[0014] Furthermore, the mounting surface of the coil disc is provided with an annular groove around its perimeter, and the annular groove is used to mount the radar plate.

[0015] Furthermore, the spacing between two adjacent magnetic cores is less than or equal to 0.5 mm, and the height difference between each magnetic core is less than 0.5 mm.

[0016] This invention also proposes an installation method for a wireless charger for an on-board power battery, comprising the following steps:

[0017] Install the radar board onto the coil plate;

[0018] Apply adhesive to the coil to form multiple straight adhesive strips passing through the center of the coil, with each pair of adjacent adhesive strips having the same included angle.

[0019] The wire harness is pressed into the winding groove of the coil disc to form a coil. The coil is fixed by the pressure plate fixture. After a preset time, the pressure plate fixture is removed.

[0020] Apply a measured amount of adhesive to the mounting surface of the coil disk, place the magnetic core after applying the adhesive, and then install the fixing bracket;

[0021] Vacuuming allows the injected adhesive to seep into the gaps and harden.

[0022] Multiple adhesive strips are arranged in a star-shaped pattern, with two inclined adhesive strips passing perpendicularly through the arc-shaped corner section of the coil.

[0023] The two ends of the wire harness are plugged into terminals, and the terminals are pressed by resistance welding equipment to fix the terminals to the wire harness.

[0024] Compared with existing technologies, this invention coats the mounting surface of the coil disc with multiple adhesive strips, each strip passing through the center of the coil disc, with the same angle between every two strips. This effectively secures the coil at corners where it is prone to warping. Furthermore, the evenly spaced adhesive strips save on adhesive application and ensure uniform coil fixation. During the encapsulation process after the coil is fixed, the height difference and spacing of the magnetic cores can be controlled within a reasonable range, resulting in a more compact structure and better conversion efficiency for the entire device. Attached Figure Description

[0025] To more clearly illustrate the technical solutions in the embodiments of the present invention, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0026] Figure 1 This is an exploded view from an embodiment of the present invention;

[0027] Figure 2 This is an exploded view of the coil and coil disk in an embodiment of the present invention;

[0028] Figure 3 This is a schematic diagram of the coil disk structure in an embodiment of the present invention;

[0029] 1. Coil disc; 2. Coil; 3. Radar plate; 4. Multiple magnetic cores; 5. Fixing bracket. Detailed Implementation

[0030] To make the technical problems to be solved, the technical solutions, and the beneficial effects of the present invention clearer, the present invention will be further described in detail below with reference to the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are merely illustrative of the present invention and are not intended to limit the present invention.

[0031] It should be noted that when a component is referred to as being "fixed to" or "set on" another component, it can be directly on or indirectly on that other component. When a component is referred to as being "connected to" another component, it can be directly connected to or indirectly connected to that other component.

[0032] In the description of this invention, it should be understood that the terms "center", "length", "width", "thickness", "upper", "lower", "front", "rear", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "outer", etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are only for the convenience of describing this invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this invention.

[0033] In the description of this invention, it should be noted that, unless otherwise explicitly specified and limited, the terms "installation," "connection," and "linking" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; they can refer to the internal communication of two components or the interaction between two components. Those skilled in the art can understand the specific meaning of the above terms in this invention according to the specific circumstances.

[0034] The principles and structure of the present invention will be described in detail below with reference to the accompanying drawings and embodiments.

[0035] like Figure 1 , 2As shown, this invention proposes a wireless charger for vehicle-mounted power batteries, comprising: a coil disc 1, a coil 2, a radar plate 3, multiple magnetic cores 4, and a fixing bracket 5. The coil disc 1 is square, with a surrounding rim on its front side, making its front side the mounting surface. The mounting surface has winding grooves for winding wire harnesses to form the coil 2. The winding path enclosed by the winding grooves is a square spiral, with rounded corners at the square corners to form arc-shaped corner segments. That is, the winding path enclosed by the winding grooves consists of alternating straight segments and arc-shaped corner segments. Before mounting the coil, adhesive is applied to form multiple adhesive strips on the mounting surface that pass through the winding grooves. Two intersecting adhesive strips pass perpendicularly through the arc-shaped corner segments of the winding grooves and pass through the center of the coil disc 1. After the adhesive strip is applied, the coil is pressed into the winding groove, thus fixing the coil within the winding groove of the coil disk. Nine magnetic cores (4) are arranged in an array, attached to the mounting surface of the coil disk and covering the coil. A fixing bracket presses down on the magnetic cores to prevent movement, ensuring the cores are fixed and have a consistent height. Multiple adhesive strips are applied to the mounting surface of the coil disk 1, each strip passing through the center of the coil disk, with equal angles between any two strips. Two intersecting strips pass perpendicularly through the curved corners of the winding groove, effectively fixing the coil at corners where it is prone to warping. The evenly spaced strips save on adhesive application while ensuring uniform coil fixation.

[0036] The winding groove on the mounting surface of coil disc 1 is formed by a partition. The center of coil disc 1 is raised, and the winding groove extends outward spirally around the raised center. The path formed by the winding groove is a square spiral. The square corners of the square spiral are rounded to form arc-shaped corner segments. That is, the path formed by the winding groove is composed of alternating straight segments and arc-shaped corner segments to form a square spiral. Coil 2 is formed by winding a single wire bundle along the winding groove into a square spiral shape (specifically, a square spiral shape on a plane).

[0037] There are four adhesive strips in total, arranged in a star shape (see details below). Figure 2 The dotted lines in the diagram should be noted to be outside the coil disc for easy identification. When applying glue, the glue can be applied within the outline of the coil disc. Specifically, there is one horizontal line, one vertical line, and two diagonally intersecting lines. The angle between each pair of glue strips is the same, so that the straight segment 21 and the curved corner segment 22 corresponding to coil 2 can be well fixed.

[0038] Specifically, after the coil 2 is installed, a certain amount of glue is applied to the mounting surface of the coil disk 1. Then, the magnetic core 4 is attached to the mounting surface of the coil disk 1, and a fixing bracket 5 is installed on the magnetic core 4, so that a glue layer is formed between the magnetic core 4 and the coil 2. At the same time, the glue layer is penetrated into the gap between the coil and the coil disk, as well as the gap between the magnetic cores, by vacuuming.

[0039] like Figure 3As shown, the mounting surface of the coil disk 1 is provided with annular grooves 12 around its perimeter, and the partitions 11 that form the wall of the winding groove are empty at the corresponding positions of the annular grooves 12. The bottom plate of the radar plate 3 is annular and is installed in the annular grooves 12. After the radar plate is installed, the surface of the bottom plate of the radar plate is flush with the bottom surface of the winding groove to avoid affecting the installation of the coil. In production, glue is applied after the radar plate is installed.

[0040] The spacing between two adjacent magnetic cores 4 is less than or equal to 0.5mm, and the height difference between each magnetic core is less than 0.5mm, making the structure compact and flat.

[0041] This invention also proposes an installation method for a wireless charger for an on-board power battery, comprising the following steps:

[0042] Four radar plates 3 are installed in the various annular grooves on the mounting surface of the coil disk 1.

[0043] Apply adhesive to the mounting surface of the coil disc to form multiple adhesive strips passing through the center of the coil disc. The multiple adhesive strips are coated on the coil disc in a star pattern, and the included angle between any two adjacent adhesive strips is equal. Among them, two intersecting adhesive strips pass perpendicularly through the arc-shaped corner section of the winding groove corresponding to the coil.

[0044] The wire harness is pressed into the winding groove of the coil disc to form a coil, and then the coil is fixed by the pressure plate. After a preset time, the pressure plate fixture is removed.

[0045] Apply a measured amount of adhesive to the mounting surface of the coil disc. After applying the adhesive, attach the magnetic core to the mounting surface of the coil disc, and then install the fixing bracket that holds the magnetic core in place.

[0046] Vacuuming allows the adhesive injected into the coil mounting surface to seep into the gaps between various components, thus curing the adhesive.

[0047] Specifically, after removing the high-temperature resistant insulating film from both ends of the wire harness, it is inserted into the terminals. Then, medium-frequency resistance welding equipment is used to apply pressure to the terminals and the wire harness. The heating effect of a short-time high current is used to melt and fix the internal parts of the Litz wire harness and the joint with the terminals.

[0048] The above description is only a preferred embodiment of the present invention and is not intended to limit the present invention. Any modifications, equivalent substitutions, and improvements made within the spirit and principles of the present invention should be included within the protection scope of the present invention.

Claims

1. A wireless charger for a vehicle-mounted power battery, characterized in that, The application relates to a coil disc and a method for manufacturing the coil disc. The coil disc comprises a coil disc mounting surface provided with a winding groove around the center of the coil disc; a plurality of rubber strips coated on the mounting surface of the coil disc, each of the rubber strips passing through the center of the coil disc, and each pair of adjacent rubber strips having the same included angle; a coil mounted in the winding groove and fixed to the coil disc through the rubber strips; a plurality of magnetic cores mounted on the mounting surface of the coil disc and covering the coil; and a fixing support pressed on the magnetic cores. The mounting surface of the coil disc is provided with a circular groove around the mounting surface, and the partition plate constituting the groove wall of the winding groove is absent at the position corresponding to the circular groove; a radar plate is mounted in the circular groove, and the surface of the bottom plate of the radar plate is flush with the bottom surface of the winding groove after the radar plate is mounted. A glue filling layer is arranged between the coil and the magnetic cores, and the glue filling layer penetrates into the gaps between the magnetic cores and the gaps between the coil and the coil disc. The path surrounded by the winding groove is a square spiral line, and the square corners of the square spiral line are rounded. The coil is formed by winding a wire bundle along the winding groove, and the coil is composed of alternating straight line segments and arc corner segments. The four rubber strips are coated on the mounting surface of the coil disc in a rice-shaped mode, and two inclined rubber strips vertically pass through the arc corner segments of the coil.

2. The wireless charger for in-vehicle power battery according to claim 1, wherein The distance between the two adjacent magnetic cores is less than or equal to 0.5 mm, and the height difference between the magnetic cores is less than 0.5 mm.

3. The in-vehicle power battery wireless charger according to claim 1, wherein, The application further discloses a method for manufacturing the coil disc.

4. The in-vehicle power battery wireless charger according to claim 3, wherein, The radar plate is mounted on the coil disc; the coil disc is glued to form a plurality of straight rubber strips passing through the center of the coil disc, and the included angle between each pair of adjacent rubber strips is the same; the wire bundle is pressed into the winding groove of the coil disc to form the coil, the coil is fixed through a pressing plate tool, the pressing plate tool is taken out after a preset time, the mounting surface of the coil disc is quantitatively filled with glue, the magnetic cores are placed after the glue is filled, and the fixing support is mounted; the glue filled in is penetrated into the gaps through vacuumizing, and the glue is solidified.

5. The in-vehicle power battery wireless charger according to claim 4, wherein, The two ends of the wire bundle are inserted into the terminals, and the terminals are pressed through a resistance welding device to fix the terminals and the wire bundle.

6. The wireless charger for in-vehicle power battery of claim 1, wherein, ​ 7. A method of installing a wireless charger for a vehicle-mounted power battery according to any one of claims 1 to 6, characterized in that, ​ ​ ​ ​ ​ ​ 8. The method of claim 7, wherein the method further comprises: positioning the wireless charger on the vehicle; and positioning the power battery on the vehicle. ​

Images