Inductive charging device for vehicle charging system

Abstract

The invention relates to an inductive charging device (1) for a vehicle charging system (2) and a method for producing an inductive charging device (1) of this type. The invention also relates to a vehicle charging system (2) having an inductive charging device (1) of this type and to an arrangement of flux conducting elements (4) for an inductive charging device (1) of this type. The invention is based on the general idea of ​​arranging an at least partially magnetically conductive filling arrangement (6) at least partially in a gap (5) between two spaced flux conducting elements (4).

Description

Technical Field

[0001] The present invention relates to an inductive charging device for a vehicle charging system and a method for producing such an inductive charging device. The present invention also relates to a vehicle charging system having such an inductive charging device and an assembly of a magnetic flux conducting element for such an inductive charging device. Background Art

[0002] To increase end-user acceptance of electric vehicles, it would be advantageous if energy transfer between a stationary energy source and the vehicle's traction battery unit were contactless or wireless. Wireless energy transfer is beneficial to end users because, for example, there is no need to carry or plug in a charging cable. Furthermore, stationary inductive charging stations can be partially buried in the ground, allowing them to better blend into urban or scenic landscapes.

[0003] DE 10 2016 115 809 A1 relates to an InFO package which is not suitable for wireless charging, in particular for inductive energy transfer in vehicle charging systems.

[0004] CN 108511153 A relates to small charging coils for consumer electronics, which are produced using a flexible printed circuit (FPC) method. These charging coils are not suitable for inductive energy transfer in vehicle charging systems.

[0005] US 2017 / 0121840 A1 relates to a method for manufacturing structures with hidden components for consumer electronics, but is not suitable for inductive energy transfer in vehicle charging systems.

[0006] US 2015 / 321566 A1 and DE 10 2012 103 315 A1 relate to inductive energy transmission devices for electric vehicles.

[0007] An inductive charging device includes a flux guiding element for guiding magnetic flux to achieve reduced transmission losses during wireless energy transfer. Custom-fitting the flux guiding elements on adjacent end faces would require laborious and expensive surface grinding of all adjacent end faces. On the other hand, omitting the custom-fitting of the flux guiding elements results in gaps between the flux guiding elements, which have a reduced magnetic flux density. Summary of the Invention

[0008] The object of the present invention is to provide an improved or at least alternative embodiment for a universal inductive charging device, which embodiment is optimized, in particular with regard to the magnetic flux guidance in the gaps between the magnetic flux guidance elements. The object of the present invention is also to provide an improved or at least an alternative method for producing an inductive charging device, which method in particular allows simpler and more economical production.

[0009] According to the invention, this object is achieved by the subject matter of the independent claims. Advantageous embodiments are the subject matter of the dependent claims.

[0010] The invention is based on the general idea that a filling component is at least partially arranged in a gap between two spaced-apart flux guiding elements, wherein the filling component is at least partially magnetically conductive.

[0011] The inductive charging device for a vehicle charging system according to the present invention includes at least one coil for generating or receiving an alternating magnetic field. The coil can be configured as a spiral flat coil, in particular a circular or rectangular spiral flat coil, or as a double-D coil. The coil can be wound substantially around a coil winding axis.

[0012] The coil can be designed as a primary coil that generates a time-varying magnetic field to enable wireless energy transfer at a predetermined transmission power. To this end, the primary coil can be supplied with the required electrical energy from a fixed energy source. If a secondary coil is within the effective range of the primary coil's time-varying magnetic field, it can be designed as a secondary coil, in which an AC voltage is induced. When the secondary coil is in a closed circuit, the AC voltage generates an electric current (AC power), which can be used, for example, to charge a traction battery unit.

[0013] The predetermined transmission power can be provided to have a maximum transmission power of at least 10 kW. A maximum transmission power of at least 10 kW is particularly advantageous for charging a vehicle's traction battery unit in order to minimize the required charging time. The predetermined transmission power enables power transmission to charge the vehicle's traction battery unit within a time span that is predetermined and / or acceptable to the end user.

[0014] The inductive charging device can at least partially form a fixed inductive charging station. The inductive charging device can at least partially form a mobile inductive charging station.

[0015] The inductive charging device further comprises at least two magnetic flux guiding elements spaced apart from each other, wherein a gap is formed between the two magnetic flux guiding elements spaced apart from each other. The term "gap" should be understood as a non-microscopic gap or a minimum gap.

[0016] The spaced flux guiding elements can each be formed and / or produced individually by a primary forming process. In other words, the spaced flux guiding elements may not be formed by separating the flux guiding elements produced in one piece or as one component.

[0017] The flux guidance element has a higher magnetic permeability than air and can be formed at least partially from a ferrimagnetic and / or ferromagnetic material. The flux guidance element can be formed as a plate element and / or a sintered plate element. The inductive charging device can have a plurality of flux guidance elements, in particular a plurality of flux guidance elements spaced apart from one another. It can be provided that all flux guidance elements are spaced apart from one another and each form at least one gap between adjacent flux guidance elements. The flux guidance element can be formed from a soft magnetic material, in particular from a soft ferrite. The flux guidance element can be formed as ferrite, in particular as a ferrite plate or a ferrite tile.

[0018] At least one gap can have a gap height and a gap width. The gap height can be defined in a direction parallel to the coil winding axis. The gap width can be defined in a direction transverse to and / or perpendicular to the coil winding axis. The gap width can be established by the distance, in a direction transverse to and / or perpendicular to the coil winding axis, between a gap face of a magnetic flux guiding element and a gap face of another magnetic flux guiding element separated by the gap. The gap face of the magnetic flux guiding element can be oriented parallel to the coil winding axis. The gap height can correspond to the thickness of the magnetic flux guiding element relative to the coil winding axis. The gap height can correspond to the distance, relative to the coil winding axis, between a transverse face of the magnetic flux guiding element facing away from the coil and a transverse face of the magnetic flux guiding element facing the coil. The transverse face facing away from the coil can be oriented transverse to and / or perpendicular to the coil winding axis. The transverse face facing the coil can be oriented transverse to and / or perpendicular to the coil winding axis. The gap width of the gap and / or minimum gap can be 1 mm to 2 mm and provide an optimal balance between manufacturing effort or required manufacturing tolerances and the gap volume.

[0019] The transverse surfaces of multiple or all flux guiding elements facing away from the coils can be substantially located and / or positioned in a common plane facing away from the coils. The transverse surfaces of multiple or all flux guiding elements facing toward the coils can be substantially located and / or positioned in a common plane facing toward the coils. The common plane facing away from the coils and the common plane facing toward the coils can be spaced apart from each other relative to the coil winding axis. The common plane facing away from the coils and the common plane facing toward the coils can be oriented parallel to each other.

[0020] Several or all flux guiding elements can have the same thickness. Several or all flux guiding elements can be constructed in a similar manner. The flux guiding elements can be spaced apart from one another in a circumferential direction around the coil winding axis and / or circumferentially around the coil winding axis. The flux guiding elements can be spaced apart from one another relative to the coil winding axis. Several or all flux guiding elements can be formed separately from one another. Several or all flux guiding elements can be formed separately from the housing, in particular from the protective housing or the shielding housing, and / or from the coil.

[0021] A filler component is at least partially disposed in the gap, wherein the filler component is at least partially magnetically conductive. The gap can be completely filled by the filler component. The filler component can be completely magnetically conductive.

[0022] A portion of the filling arrangement is considered to be magnetically permeable here and hereinafter when this portion has a relative magnetic permeability of greater than 1.1 and / or preferably at least 1.5 and / or preferably at least 10.

[0023] A part of the filling arrangement is considered to be magnetically neutral here and hereinafter when this part has a relative magnetic permeability of 0.9 to 1.1, in particular of 1.

[0024] It can be provided that at least a portion of the filling arrangement has a relative magnetic permeability of at least 50, in particular at least 100.

[0025] By means of the filling arrangement, an optimized and, if applicable, complex flux guidance with regard to energy transmission can be provided in at least one gap between two spaced flux guidance elements.

[0026] It can be provided that each gap between spaced and adjacent flux guiding elements is at least partially or completely filled by a filling assembly of this type.It can be provided that the construction of the filling assembly is formed substantially similarly for a plurality of gaps or for all gaps.

[0027] In an advantageous further development of the solution according to the invention, it is provided that the filling component comprises flux-guiding particles. The filling component can comprise a plurality of flux-guiding particles formed separately from one another.

[0028] The flux guiding particles can be at least partially magnetically conductive. They can have a relative magnetic permeability of at least 50, in particular at least 100. They can be formed at least partially from ferrimagnetic and / or ferromagnetic and / or soft magnetic materials and / or soft ferrites. Prior to introduction into the gap, the flux guiding particles can be present as pourable particles and / or as free-flowing particles and / or as loose particles and / or as a loose powder. The flux guiding particles can be formed as fine particles, which, for example, have a size smaller than the thickness of the flux guiding element.

[0029] The magnetic properties of the filling component can be adjusted via the amount and / or number and / or position of the flux-guiding particles.

[0030] The flux guiding particles can each have a spherical shape. Here, the flux guiding particles can each have a diameter of 20 μm to 500 μm, in particular 150 μm. This allows for an optimized gap filling or an optimized reduction of the residual air content in the gap.

[0031] The size distribution and particle shape do not have to be uniform but can correspond to a continuous graded curve. Thus, a maximum volume fill or a minimum pore volume can be achieved. The size distribution of the diameters of the flux guiding particles, in particular a continuous or constant size distribution, can be from 20 μm to 500 μm. The size distribution of the diameters of the flux guiding particles can be selected to achieve a maximum volume fill or a minimum pore volume or a minimum amount of residual air.

[0032] In an advantageous further development of the solution according to the invention, at least a portion of the flux guiding particles respectively form a particle shape that deviates from a spherical shape, and / or at least a portion of the flux guiding particles respectively form a particle shape of a rotational ellipsoid, and / or at least a portion of the flux guiding particles respectively form a particle shape of a triaxial ellipsoid, and / or at least a portion of the flux guiding particles respectively form a flat, in particular lens-shaped or plate-shaped, particle shape.

[0033] All the flux guiding particles and / or most of the flux guiding particles, especially 80% of the total number of flux guiding particles in the gap, can respectively form a particle shape that deviates from a spherical shape and / or a particle shape of a rotational ellipsoid and / or a particle shape of a triaxial ellipsoid and / or a flat, especially lens-shaped or plate-shaped particle shape.

[0034] In the case of particle shapes that deviate from a spherical shape, the maximum size of the flux guiding particles can be configured such that the flux guiding particles can be surrounded and / or enclosed by an imaginary sphere, wherein the imaginary sphere has a diameter of 20 μm to 500 μm, in particular 150 μm. This allows for optimal gap filling or an optimal reduction of the residual air content in the gap.

[0035] Even in the case of particle shapes that deviate from spherical shapes, the size distribution and particle shape do not have to be uniform, but can correspond to a continuous graded curve. This allows for maximum volume filling or minimum pore volume. The size distribution of the flux-guided particles, in particular a continuous or constant size distribution, can be determined in the case of particle shapes that deviate from spherical shapes by the diameter of an imaginary enclosing sphere, with this diameter being between 20 μm and 500 μm. The size distribution of the diameter of the imaginary enclosing sphere can be selected so as to achieve maximum volume filling or minimum pore volume or minimum residual air volume.

[0036] The outer surface of the ellipsoid can be defined by an imaginary rotation of the ellipse about one of its axes. Here, the ellipse has a major semi-axis and a minor semi-axis, with the imaginary rotation of the ellipse occurring about the minor semi-axis. In the case of flux guiding particles that at least partially have the particle shape of a spheroid of rotation, the ratio of the major semi-axis to the minor semi-axis can be greater than 1 and less than or equal to 3. This allows for optimized gap filling or an optimized reduction of the residual air content in the gap.

[0037] The outer surface of a flat, in particular lens-shaped or plate-shaped particle can also be defined by an imaginary rotation of an ellipse about one of its axes. The ellipse has a major semi-axis and a minor semi-axis, with the imaginary rotation of the ellipse occurring about the minor semi-axis. For flux guiding particles having at least partially flat, in particular lens-shaped or plate-shaped particle shapes, the ratio of the major semi-axis to the minor semi-axis can be greater than 3 and less than or equal to 10.

[0038] In the case of a spheroidal and / or flat, in particular lens-shaped or plate-shaped, particle shape, the semi-axis of the flux guiding particles in the gap can be oriented such that the semi-axis is oriented parallel to the coil winding axis.

[0039] These flux-guiding particles can be oriented in the gap so that they have a smaller extension in a direction parallel to the coil winding axis than in a direction transverse to and / or perpendicular to the coil winding axis. Thus, a naturally oriented layer structure can be achieved when introducing the flux-guiding particles by trickling, pouring, or similar methods, or by injection of the filler matrix material or by sedimentation in a low-viscosity suspension. Furthermore, such flux-guiding particles can be used to create anisotropic permeability in the gap, wherein the permeability of the filler component in a direction parallel to the coil winding axis is smaller than the permeability of the filler component in a direction transverse to and / or perpendicular to the coil winding axis.

[0040] These flux guiding particles can reduce the magnetic field scattered from the plane of the flux guiding element and / or reduce eddy current losses in eg adjacent metal parts.

[0041] In an advantageous further development of the solution according to the invention, at least a portion of the flux guiding particles is introduced into the gap as a filler and / or at least a portion of the flux guiding particles is introduced into the gap as a loose filler and / or at least a portion of the flux guiding particles is introduced into the gap as a compressed filler.

[0042] The magnetic properties of the filler can be adjusted by the quantity and / or number of flux guiding particles and the corresponding pressurization and / or compression and / or compaction. For example, the filler, in particular loose filler and / or compressed filler, can be introduced into the gap by trickling and / or shaking and / or blowing in the flux guiding particles while the flux guiding element is fixed in position.

[0043] Loose fillers can partially contain air, thus forming, for example, a mixture of flux guiding particles and air. Loose fillers can have a higher air content than compressed fillers. Compressed fillers can be formed such that no or reduced air inclusions form in the volume in which the compressed filler is provided.

[0044] Loose fillers made of flux guiding particles introduced into gaps of unknown contour can be compressed using hydraulic or pneumatic pressure. To this end, the structure of the flux guiding element, particularly the ferrite tiles, and the filler assembly can be positioned between two rubber bellows, where the required compression pressure can be set. The elastic rubber material adapts to the gap contour and compresses the loose filler in the gap into a compressed filler. This reduces the fill height in the gap. This method can also be applied to fillers surrounded by paper.

[0045] The filling of flux-guiding particles, in particular the compressed filling, can be formed by a shaping method of ferrite powder, which is also used for the production (shaping) of green compacts in a sintering process.

[0046] To compress the flux guiding particles in the gap, a pressure of 1 MPa (e.g., loose compression) to 100 MPa (e.g., an easily handled independent green body) can be used. Preferably, to compress the flux guiding particles in the gap, a pressure of 10 to 20 MPa can be used, which is easily and economically manageable in terms of manufacturing technology and process.

[0047] In an advantageous further development of the solution according to the invention, the filler, in particular a loose filler and / or a compressed filler, is arranged in the gap by means of a separate position fixing device, wherein the separate position fixing device is arranged in the gap without a material connection to the magnetic flux guiding element forming the gap, and / or the filler, in particular a loose filler and / or a compressed filler, is arranged in the gap by means of an integral position fixing device, wherein the integral position fixing device is at least partially connected to the magnetic flux guiding element forming the gap in a materially connected manner.

[0048] The separation position fixing device can be moved relative to the flux guiding element forming the gap. Such a separation position fixing device can, for example, remain permanently arranged in the gap or can only be arranged in the gap in a time-limited manner for filling with a filler.

[0049] The separation position fixing means can be formed from a magnetically neutral material.

[0050] The integrated position fixing device can be formed partly by the filling to be fixed, in particular by the loose filling to be fixed and / or the compressed filling to be fixed itself. Alternatively or additionally, the integrated position fixing device can be formed by a part of the filling component that does not correspond to the filling to be fixed, in particular does not correspond to the loose filling and / or the compressed filling.

[0051] The integrated position fixing device can be formed from a magnetically neutral material. The integrated position fixing device can form a material-connected connection of the flux guiding elements forming the gap.

[0052] In an advantageous further development of the solution according to the invention, it is provided that the separation position fixing device has a shell, in particular a shell of paper material, for completely enclosing the filler, in particular the flux guiding particles of the loose filler and / or compressed filler, wherein the shell, in particular the shell of paper material, together with the filler, in particular the flux guiding particles of the loose filler and / or compressed filler, forms an encapsulation.

[0053] The filler in the package, especially the loose filler, can be compressed before the package is inserted into the gap to form a compressed filler. The filler in the package, especially the loose filler, can be compressed after the package is inserted into the gap to form a compressed filler.

[0054] The housing can prevent the flux-guiding particles of the filler from escaping. The housing can be formed, for example, from a paper material and / or can be formed into a paper shell. The housing and / or the paper material can be a durable, temperature-stable paper type. The housing can be magnetically neutral.

[0055] Fillings for stationary flux guiding particles, in particular loose and / or compressed fillings, can thus be encapsulated in elongated paper-wrapped packaging that can be easily pressed into the gap. These packagings can form semi-finished products for easier production of inductive charging devices.

[0056] In an advantageous further development of the solution according to the invention, it is provided that the filler, in particular the loose filler and / or the compressed filler, which is arranged in the gap with an integrated position fixing device forms a porous solid layer, wherein the porous solid layer is formed by flux guiding particles, which have a surface coating for material connection to one another and for at least partially material connection to the flux guiding element forming the gap.

[0057] It can be provided that several or all layers of the filling component are formed as porous solid layers. Several or all porous solid layers can be arranged one above the other and / or stacked relative to the coil winding axis.

[0058] The flux guiding particles with a surface coating can be present as pourable particles and / or as free-flowing particles and / or as loose particles and / or as loose powder before being introduced into the gap. The flux guiding particles with a surface coating can be formed as fine particles, for example, having a size smaller than the thickness of the flux guiding element.

[0059] The flux guiding particles with a surface coating can have a flux guiding particle core which is formed at least partially from a ferrimagnetic material and / or a ferromagnetic material and / or a soft magnetic material and / or a soft magnetic ferrite.

[0060] The surface coating of the flux guiding particles can be thin compared to the size of the flux guiding particles. The surface coating can be formed, for example, from a meltable material, in particular a thermoplastic. The surface coating can be magnetically neutral.

[0061] The surface coating can be a material with good thermal conductivity. The surface coating can have a thermal conductivity and / or thermal conductivity coefficient of at least 0.5 W / (mK), in particular at least 1.0 W / (mK), or in particular at least 10.0 W / (mK). This improves the thermal conductivity through the structure to an externally arranged heat sink, for example.

[0062] The flux guiding particles with a surface coating can be introduced into the gap, for example, through a nozzle and / or by an injection or pressing process, wherein the surface coating first melts and then solidifies, thereby forming a porous solid layer.

[0063] The porous solid layer can form a materially connected mechanical connection between the gap face of a flux guiding element and the gap face of an adjacent flux guiding element separated by a gap, thereby improving the mechanical stability and / or strength of the overall structure.

[0064] In an advantageous further development of the solution according to the invention, it is provided that the filling component has at least one embedding matrix for embedding the flux guiding particles and / or that at least some of the flux guiding particles are introduced as filler into at least one embedding matrix of the filling component.

[0065] The embedding matrix can be formed from an embedding material for embedding magnetic flux guiding particles. The embedding matrix can be formed from a magnetically neutral embedding material. The embedding matrix can be formed from an embedding material with good thermal conductivity. The embedding matrix can have a thermal conductivity and / or thermal conductivity coefficient of at least 0.5 W / (mK), in particular at least 1.0 W / (mK), or in particular at least 10.0 W / (mK). This improves the thermal conductivity through the structure, for example, to an externally arranged heat sink.

[0066] The embedding matrix can form a material-bonded mechanical connection between the gap face of a flux guiding element and the gap face of an adjacent flux guiding element separated by the gap, thereby improving the mechanical stability and / or strength of the overall structure.

[0067] The magnetic properties of the filling component can be adjusted by the amount and / or number of flux-guiding particles embedded in the matrix.

[0068] In an advantageous further development of the solution according to the invention, it is provided that the embedding matrix with embedded flux guiding particles is introduced into the gap in the form of a paste, or that the embedding matrix with embedded flux guiding particles is introduced into the gap in the form of a paste, wherein the embedding matrix is ​​formed by an actively hardening matrix material, in particular an adhesive material, or that the embedding matrix with embedded flux guiding particles is introduced into the gap in the form of a paste, wherein the embedding matrix is ​​formed by a passively hardening matrix material, in particular a thermoplastic material and / or a thermosetting plastic material and / or an elastomer and / or a hydraulic material.

[0069] The embedding matrix with embedded flux-guiding particles can be introduced into the gap by dispensing and / or encapsulating and / or extruding.

[0070] The embedding matrix with embedded flux guiding particles can form a materially connected mechanical connection between the gap face of a flux guiding element and the gap face of an adjacent flux guiding element separated by a gap, thereby improving the mechanical stability and / or strength of the overall structure.

[0071] The embedding matrix with the embedded pasty flux-guiding particles can be introduced into the gap as an injection-molded layer by injection molding.

[0072] In an advantageous further development of the solution according to the invention, it is provided that the embedding matrix with the embedded flux-guiding particles forms a foil element, wherein at least one such foil element is introduced into the gap.

[0073] The embedding matrix of the foil element can be, for example, an adhesive matrix and / or a polymer matrix and / or a thermoplastic matrix and / or a thermosetting plastic matrix and / or an elastomer and / or a hydraulic material, which hardens before the foil element is introduced into the gap.

[0074] The foil element can thus be formed into a hardened, solid layer before being introduced into the gap. The foil layer can thus be provided as a semi-finished product that can be easily and economically used during the manufacturing process of the inductive charging device. The predetermined foil thickness can be smaller than the gap height of the gap and / or smaller than the gap width of the gap. The predetermined foil thickness allows the gap height and / or gap width of the gap to be adapted by the number of foil elements. If, for example, different gap heights and / or gap widths are predetermined in different embodiments of the inductive charging device, adaptation can be easily achieved by increasing or decreasing the number of foil elements.

[0075] A plurality of foil elements can be arranged in the gap, which foil elements can be arranged flat relative to the coil winding axis and / or stacked. A plurality of foil elements can be arranged in the gap, which foil elements can be arranged adjacent to each other transversely and / or perpendicularly to the coil winding axis and / or stacked.

[0076] In an advantageous further development of the solution according to the invention, it is provided that the filling component has a plurality of layers.

[0077] The gap can be completely filled by a filling assembly having multiple layers. At least two layers, or all layers, can be formed from layers of different materials. At least two layers, or all layers, can be formed from layers of different solids. At least two layers, or all layers, can have different magnetic properties. At least two layers, or all layers, can particularly have different magnetic permeabilities and / or magnetic permeabilities. At least two layers, or all layers, can be formed from layers of similar materials having different magnetic properties and / or different magnetic permeabilities and / or different magnetic permeabilities.

[0078] The magnetic properties and / or magnetic permeability and / or magnetic permeability of the layers can vary relative to the coil winding axis. The magnetic properties and / or magnetic permeability and / or magnetic permeability of each layer can increase in sections and / or remain substantially constant in sections and / or decrease in sections relative to the coil winding axis as the distance from the coil increases.

[0079] It can be provided that at least one layer of the filling component and / or a plurality of layers of the filling component have a relative magnetic permeability of at least 50, in particular at least 100.

[0080] It can be provided that at least one layer of the filling component and / or a plurality of layers of the filling component are magnetically neutral.

[0081] The multilayer structure of the filling component allows different primary functions to be assigned to the layers in the gap. Thus, for example, it can be provided that the primary function of one layer is to guide the magnetic flux in the gap, while the primary function of another layer is to form a mechanically resistant filling component.

[0082] It can be provided that each gap between spaced and adjacent flux guiding elements is completely filled with such a filling component having a plurality of layers. It can be provided that the multilayer structure of the filling component is formed substantially similarly for a plurality of gaps or for all gaps.

[0083] For gaps with different orientations, it can be advantageous to tailor the structure of the filling assembly layers and / or the filling material to the expected magnetic flux in the gap. Gaps oriented orthogonally to the magnetic flux direction can, for example, be filled with a material with high magnetic properties or high relative magnetic permeability. For gaps extending parallel to the magnetic flux direction, other properties (e.g., thermal and / or mechanical properties) can be prioritized.

[0084] At least one layer of the filling component or a plurality of layers of the filling component or all layers of the filling component can be connected in a materially bonded manner to two flux guidance elements which are spaced apart from one another by a gap.

[0085] It can be provided that a plurality of layers or all layers of the filling component are formed as adhesive layers. A plurality of adhesive layers or all adhesive layers can be arranged so as to be superposed and / or stacked relative to the coil winding axis.

[0086] It can be provided that a plurality of layers or all layers of the filling component are formed as injection-molded layers. A plurality of injection-molded layers or all injection-molded layers can be arranged one above the other and / or stacked relative to the coil winding axis.

[0087] Adhesive and / or injection-molded layers that can be introduced into gaps of unknown contour can be compressed, for example, by hydraulic or pneumatic pressure after introduction. To this end, the structure of the flux guidance element, in particular the structure of the ferrite tiles, and the structure of the filling component can be positioned between two rubber bellows, where the required compression pressure can be set. The elastic rubber material adapts to the contour of the gap and compresses the adhesive and / or injection-molded layer in the gap. This allows the filling height of the layer in the gap to be reduced.

[0088] It can be provided that at least one layer of the filling component is formed as a semi-finished product which is inserted into the gap and / or that the filling component is formed as a semi-finished product which is inserted into the gap.

[0089] It can be provided that at least two layers of the filling component have different magnetic properties.

[0090] At least two layers or all layers can in particular have different magnetic permeabilities and / or magnetic permeabilities.At least two layers or all layers can be formed from similar material layers having different magnetic properties and / or different magnetic permeabilities and / or different magnetic permeabilities.

[0091] In an advantageous further development of the solution according to the invention, at least one layer of the filling component forms a magnetically conductive layer and / or at least one layer of the filling component forms a magnetically neutral layer.

[0092] It can be provided that at least one magnetically conductive layer of the filling component has a relative magnetic permeability of at least 50, in particular at least 100.

[0093] At least one magnetically conductive layer can include magnetic flux guiding particles. It can be provided that at least a portion of these magnetic flux guiding particles have a particle shape that deviates from a spherical shape, and / or at least a portion of these magnetic flux guiding particles have a particle shape that is a spheroid of rotation, and / or at least a portion of the magnetic flux guiding particles have a particle shape that is a triaxial ellipsoid, and / or at least a portion of the magnetic flux guiding particles have a flat, in particular lens-shaped or plate-shaped, particle shape.

[0094] The at least one magnetically conductive layer can be formed by a filling of flux guiding particles, in particular by a loose filling of flux guiding particles or a compressed filling of flux guiding particles.

[0095] At least one magnetically conductive layer can be configured such that the separation position fixing device has a shell, in particular a shell of paper material, for completely enclosing the magnetic flux guiding particles of the filler, in particular the loose filler and / or the compressed filler, wherein the shell, in particular the shell of paper material, forms an encapsulation together with the magnetic flux guiding particles of the filler, in particular the loose filler and / or the compressed filler.

[0096] Such a particle encapsulation, which can be introduced into a gap of unknown contour, can be compressed, for example, by hydraulic or pneumatic pressure after introduction. To this end, the structure of the flux guidance element, in particular the structure of the ferrite tiles, and the structure of the filling component can be positioned between two rubber bellows, where the required compression pressure can be set. The elastic rubber material adapts to the gap contour and compresses the particle encapsulation in the gap. This allows the filling height of the particle encapsulation in the gap to be reduced.

[0097] The filling of flux-guiding particles, in particular the compressed filling, can be formed by a shaping method of ferrite powder, which is also used for the production (shaping) of green compacts in a sintering process.

[0098] To compress the flux guiding particles in the gap, a pressure of 1 MPa (e.g., loose compression) to 100 MPa (e.g., an easily handled independent green body) can be used. Preferably, to compress the flux guiding particles in the gap, a pressure of 10 to 20 MPa can be used, which is easily and economically manageable in terms of manufacturing technology and process.

[0099] At least one magnetically conductive layer can be constructed so that a filler, in particular a loose filler and / or a compressed filler, arranged in the gap by means of an integrated position fixing device forms a porous solid layer, wherein the porous solid layer is formed by magnetic flux guiding particles having a surface coating for being connected to each other in a materially connected manner and for being connected to the magnetic flux guiding element forming the gap in an at least partially materially connected manner.

[0100] The at least one magnetically conductive layer can comprise at least one embedding matrix for embedding the flux-guiding particles and / or can be designed such that at least some of the flux-guiding particles are introduced as a filler into the at least one embedding matrix of the magnetically conductive layer.

[0101] At least one magnetically conductive layer can be constructed so that an embedding matrix with embedded flux-guiding particles is introduced into the gap in the form of a paste, or an embedding matrix with embedded flux-guiding particles is introduced into the gap in the form of a paste, wherein the embedding matrix is ​​formed by an actively hardening matrix material, in particular an adhesive material, or an embedding matrix with embedded flux-guiding particles is introduced into the gap in the form of a paste, wherein the embedding matrix is ​​formed by a passively hardening matrix material, in particular a thermoplastic material and / or a thermosetting plastic and / or an elastomer and / or a hydraulic material.

[0102] At least one magnetically conductive layer can be formed such that the embedding matrix with the embedded flux-guiding particles forms a foil element, wherein at least one such foil element is introduced into the gap.

[0103] By means of the magnetically permeable layer, the magnetic flux can be concentrated in the layer when transitioning between two flux elements separated by a gap.

[0104] The at least one magnetically neutral layer of the filling component can be formed from a magnetically neutral casting material.

[0105] The at least one magnetically neutral layer of the filling component can form an air layer and / or a magnetically neutral solid layer.

[0106] The at least one magnetically neutral layer of the filling component can be a foil element, in particular a foil element without flux-guiding particles.

[0107] The at least one magnetically neutral layer of the filling component can be an adhesive layer, in particular an adhesive layer without flux-guiding particles.

[0108] The at least one magnetically neutral layer of the filling component can be an injection-molded layer, in particular an injection-molded layer free of flux-guiding particles.

[0109] The magnetically neutral layer of the filler component can be a material with good thermal conductivity. The magnetically neutral layer of the filler component can have a thermal conductivity and / or thermal conductivity coefficient of at least 0.5 W / (mK), in particular at least 1.0 W / (mK), or in particular at least 10.0 W / (mK). This improves the thermal conductivity through the structure to an externally arranged heat sink, for example.

[0110] In an advantageous further development of the solution according to the invention, it is provided that at least one magnetically conductive layer of the filling component is arranged between two magnetically neutral layers of the filling component and / or that the magnetically conductive layer component of the filling component is arranged to touch at least one magnetically neutral layer of the filling component.

[0111] At least one magnetically conductive layer of the filler component can be arranged relative to the coil winding axis between two magnetically neutral layers, in particular between two magnetically neutral outer layers, of the filler component.

[0112] In an advantageous further improvement of the solution according to the invention, it is provided that at least one magnetically neutral layer of the filling component is an air layer, and / or at least one magnetically neutral layer of the filling component is formed by a magnetically neutral solid layer, and / or at least one magnetically neutral solid layer of the filling component forms a magnetically neutral outer layer, which is partially formed within the gap and partially formed outside the gap.

[0113] In an advantageous further development of the solution according to the invention, it is provided that the outer layer is formed as a casting, into which the coil is embedded. The casting can be formed from a casting compound. The casting and / or the casting compound can form a magnetically neutral solid layer.

[0114] By using an air layer and / or a magnetically neutral solid layer, for example, a targeted scattering of the magnetic field can be brought about within the housing in order to reduce the occurrence of eddy currents and / or eddy current losses in adjacent components.

[0115] While the air layer and / or magnetically neutral solid layer nominally transmits almost no magnetic flux, the magnetic field scatters in this region, significantly weakening it outside the confines of the flux guidance element. This reduces the magnetic field on the side of the flux guidance element facing away from the coil. This minimizes eddy current losses in the housing and other electrical conductors within the effective range of the magnetic field.

[0116] In an advantageous further development of the solution according to the invention, provision is made for at least two gaps spaced apart from one another to be formed, in which a filling component with at least one magnetically neutral layer is respectively arranged, wherein the magnetically neutral layers are connected to one another.

[0117] The interconnected neutral layers in at least two gaps spaced apart from each other can be directly connected to each other. The interconnected neutral layers can form an outer layer.

[0118] Provision can be made for a positive fit to be formed, in particular by outer layers between the flux guidance elements forming the gap, in order to form the flux guidance elements separated by the gap into a stable, one-piece flux guidance device with gap filling and / or profiled spacers.

[0119] For form fit, at least one outer layer of the filling component can contact and / or touch the lateral surfaces of two flux guiding elements separated by a gap, facing the coil, and / or the lateral surfaces of two flux guiding elements separated by a gap, facing away from the coil, and / or can be connected to them in a materially connected manner.

[0120] It can be provided that a positive fit is formed, in particular by means of outer layers between the flux guidance elements, in order to form a component that can be mounted in one piece.

[0121] In an advantageous further development of the solution according to the invention, it is provided that at least one layer of the filling component comprises flux guiding particles, and / or at least one layer of the filling component comprises flux guiding particles, wherein the concentration of the flux guiding particles varies spatially within the layer, and / or at least two layers of the filling component each comprise flux guiding particles, wherein the concentration of the flux guiding particles is different in the two layers.

[0122] For example, it can be provided that the filling component is formed in the following manner: first, a magnetically neutral castable material having a small amount of flux-guiding particles is introduced, wherein the castable material has a lower viscosity when introduced into the gap so that the flux-guiding particles aggregate or concentrate in the layer area of ​​the filling component due to gravity, thereby forming a filling component that forms magnetic properties that gradually change relative to the coil winding axis. Therefore, the magnetic properties of the filling component can be adapted in a desired manner relative to the coil winding axis and / or relative to the gap height. The process can be accelerated by a vibrator and / or a vibration device. It can be provided that, after the process, the filling component forms at least one magnetically neutral layer, in particular, the magnetically neutral layer is substantially free of flux-guiding particles, and forms another layer in which flux-guiding particles are introduced. Compared to the magnetically neutral layer, the layer with flux-guiding particles can be arranged closer to the coil relative to the coil winding axis. The magnetically neutral layer can be a magnetically neutral solid layer.

[0123] In an advantageous further development of the solution according to the invention, at least one magnetically neutral solid layer of the filling component, in particular the magnetically neutral outer layer, is formed from a magnetically neutral casting material, and / or the magnetically neutral outer layer is formed for separating and / or connecting and / or fixing and / or positioning components of the inductive charging device, and / or the flux guiding elements spaced apart from each other form an integrally mountable component together with the filling component in the gap.

[0124] The outer layer can be formed outside the gap for spacing and / or connecting and / or fixing and / or positioning the inductive charging device.

[0125] The outer layer can be formed to separate and / or connect and / or fix and / or position the protective shell. The outer layer can be formed to separate and / or connect and / or fix and / or position the shielding shell. The outer layer can be formed to separate and / or connect and / or fix and / or position the coil. The outer layer can be formed to separate and / or connect and / or fix and / or position the flux guiding elements separated by the gap.

[0126] The connection can form a material-bonded connection.The outer layer can form a separating element for separation, in particular a separating element outside the gap.

[0127] The outer layer can be formed as a magnetically neutral solid layer. Such an outer layer can be hardened (eg thermally hardened) in a process step together with at least one further layer having flux-guiding particles.

[0128] The outer layer can serve as a connection for wires or coils and / or power electronics and / or electromagnetic shielding outside the gap. Furthermore, the mechanical connection, in the form of a material connection, provided by the filler component between the gap face of a flux guiding element and the gap face of an adjacent flux guiding element separated by the gap, can provide additional stability and strength to the overall structure.

[0129] Provision can be made for a positive fit, in particular by means of outer layers between the flux guidance elements, to form the flux guidance elements separated by gaps into a stable, one-piece flux guidance device with gap filling and profiled spacers.

[0130] For form fit, at least one outer layer of the filling component can contact and / or touch the lateral surfaces of two flux guiding elements separated by a gap, facing the coil, and / or the lateral surfaces of two flux guiding elements separated by a gap, facing away from the coil, and / or be connected to them in a materially connected manner.

[0131] In an advantageous further development of the solution according to the invention, it is provided that the inductive charging device has a housing which forms a housing interior, wherein the coil and the flux conducting element are arranged in the housing interior.

[0132] The shell can be a potting compound shell that is formed integrally from a potting compound, fills the shell interior, and surrounds the components of the inductive charging device.

[0133] The housing can be formed from at least two parts, wherein such a two-part housing can have a protective shell for protection against external influences and a shielding shell formed separately from the protective shell for shielding against alternating electromagnetic fields.

[0134] The protective shell can form a trough-shaped protective shell.

[0135] The protective shell can be formed from a non-conductive material.The protective shell can be formed from a plastic material and / or from a composite material and / or from a fiber-reinforced composite material.

[0136] The shielding shell can form a shielding body for electromagnetic shielding. For example, the shielding body can be used to shield vehicle components from electromagnetic fields. The shielding shell can form and / or comprise a shielding plate made of a metal material. The metal material can be, for example, aluminum. The shielding shell can be formed as a flat body and / or a plate-shaped body.

[0137] The shielding shell and the protective shell can form a shell interior and delimit the shell interior with respect to the external environment, in particular delimit the shell interior in a fluid-tight manner.

[0138] The flux guidance element can be arranged in the housing interior at a distance from the shielding shell and / or at a distance from the protective shell and / or at a distance from the coil. The coil can be arranged between the flux guidance element and the protective shell relative to the coil winding axis. The coil can be arranged at a distance from the flux guidance element and the protective shell relative to the coil winding axis. The free space between the spaced components in the housing interior can be partially and / or completely filled, for example, with at least one casting compound, in particular a thermally conductive casting compound.

[0139] In an advantageous further development of the solution according to the invention, the inductive charging device has more than two flux guidance elements spaced apart from one another, wherein a plurality of gaps are formed between the flux guidance elements spaced apart from one another, wherein a filling component is provided at least partially in each case only in a portion of the gaps. In other words, the inductive charging device has a plurality of gaps between the plurality of flux guidance elements, wherein only some, but not all, of the gaps have a filling component.

[0140] In an advantageous further development of the solution according to the invention, each gap has a gap height, a gap width, and a gap length, wherein the filling component arranged in at least one gap is formed from different layers with respect to the gap height and / or with respect to the gap length. The different layers can be formed as layers of different materials.

[0141] In other words, the filling component arranged in the gap can be constructed in different material layers in the thickness direction of the flux guidance element and / or can have a variable layer structure in the longitudinal direction of the gap.

[0142] The term "relative to the gap height" can be understood to mean an arrangement relative to a gap height direction parallel to the coil winding axis. The term "relative to the gap length" can be understood to mean an arrangement relative to a gap length direction that is substantially perpendicular, in particular perpendicular and / or transverse to the coil winding axis. The term "relative to the gap width" can be understood to mean an arrangement relative to a gap width direction that is substantially perpendicular, in particular perpendicular and / or transverse to the coil winding axis.

[0143] The gap width direction and the gap length direction are oriented substantially perpendicularly to one another, in particular perpendicularly and / or transversely to one another. The gap length direction is oriented substantially parallel to, in particular parallel to, the gap surface or two gap surfaces forming the gap. The gap width direction is oriented substantially parallel to, in particular parallel to, the transverse surfaces of the flux guiding element forming the gap.

[0144] In an advantageous further development of the solution according to the invention, it is provided that each gap has a gap height, a gap width and a gap length, wherein the filling component arranged in at least one gap is formed by different material layers relative to the gap length, wherein at least one of these layers formed differently relative to the gap width is a magnetically neutral layer, in particular an air layer.

[0145] In other words, the gap partially filled with the filling component has at least one partial region in the longitudinal direction which is only filled with air. Therefore, in this partial region, only a continuous air layer is formed relative to the gap height.

[0146] The present invention also relates to an arrangement for magnetic flux guidance elements of an inductive charging device according to the present invention. The arrangement comprises at least two magnetic flux guidance elements spaced apart from one another, which can be arranged inside a housing of the inductive charging device. At least one gap is formed between the two magnetic flux guidance elements spaced apart from one another, wherein the gap is partially or completely filled with a filling component having multiple layers, wherein the magnetic flux guidance elements spaced apart from one another and the filling component in the gap together form an integrally mountable component.

[0147] To this end, the filling component can form at least one outer layer, which is formed partly within the gap and partly outside the gap.

[0148] The outer layer can be formed to separate and / or connect and / or fix and / or position the components of the inductive charging device inside the housing. The outer layer can be formed outside the gap to separate and / or connect and / or fix and / or position the components of the inductive charging device inside the housing.

[0149] The outer layer can be formed to separate and / or connect and / or fix and / or position the shielding shell. The outer layer can be formed to separate and / or connect and / or fix and / or position the protective shell. The outer layer can be formed to separate and / or connect and / or fix and / or position the coil. The outer layer can be formed to separate and / or connect and / or fix and / or position the flux guiding elements separated by the gap.

[0150] The connection can form a material-bonded connection.The outer layer can form a separating element for separation, in particular a separating element outside the gap.

[0151] The outer layer can be formed as a substantially magnetically neutral solid layer. Such an outer layer can be hardened (for example thermally hardened) in a process step together with at least one further layer comprising magnetic field conductor particles.

[0152] The outer layer can be used outside the gap to connect wires or coils, components of power electronics, and / or electromagnetic shielding. Furthermore, the mechanical connection, in the form of a material connection, provided by the filler component between the gap face of a flux guiding element and the gap face of an adjacent flux guiding element separated by the gap, can provide additional stability and strength to the overall structure.

[0153] Provision can be made for a positive connection to be formed, in particular by outer layers between the flux guidance elements forming the gap, in order to form the flux guidance elements separated by the gap into a stable, integral magnetic field conductor arrangement with gap filling and formed spacers.

[0154] For form-fitting, at least one outer layer of the filling component can contact and / or touch the lateral surfaces of two magnetic field conductors separated by a gap, facing the coil, and / or the lateral surfaces of two flux guiding elements separated by a gap, facing away from the coil, and / or can be connected to them in a materially connected manner.

[0155] It can be provided that a positive connection is formed, in particular by forming a positive connection between the magnetic field conductors, in order to form a component that can be mounted in one piece.

[0156] The invention further relates to a vehicle charging system having a fixed inductive charging station formed at least partially by an inductive charging device according to the invention and / or having a mobile inductive device attachable to a vehicle formed at least partially by an inductive charging device according to the invention.

[0157] For this purpose, a stationary inductive charging station can be connected to a stationary energy source. The stationary inductive charging station can, for example, be embedded in the driving surface. The stationary inductive charging station can form the primary coil, while the vehicle's mobile inductive charging device can form the secondary coil.

[0158] The primary coil of a stationary inductive charging station can generate a time-varying magnetic field to enable wireless energy transfer at a predetermined transmission power. To this end, the primary coil can be supplied with the required electrical energy from a stationary energy source. The secondary coil of a mobile inductive charging device can be configured so that an AC voltage is induced in the secondary coil when it is within the effective range of the time-varying magnetic field of the primary coil of the stationary inductive charging station. When the secondary coil is in a closed circuit, the AC voltage generates an electrical current (AC power) that can be used, for example, to charge a vehicle's traction battery pack.

[0159] The present invention also relates to a vehicle for use with a vehicle charging system according to the present invention, comprising a mobile inductive charging device according to the present invention and a traction battery unit electrically coupled to the mobile inductive charging device and capable of supplying electrical energy via the mobile inductive charging device. The vehicle can be an electric vehicle having at least one rotating electrical machine, wherein the rotating electrical machine provides the vehicle's drive and is supplied with electrical energy via the traction battery unit. The vehicle can be a road vehicle, in particular a non-track road vehicle. The vehicle can be an electric vehicle, a hybrid vehicle, or a plug-in hybrid vehicle.

[0160] The inductive charging device can be arranged in the vehicle near the driving surface.

[0161] The present invention further relates to a method for producing an inductive charging device according to the invention, wherein at least one gap is filled with a filling component before magnetic flux guidance elements spaced apart from one another are inserted into the interior of a housing, wherein the magnetic flux guidance elements spaced apart from one another together with the filling component in the gap form a component that can be installed integrally and is inserted into the interior of the housing.

[0162] Upstream injection molding or extrusion of the filler component and subsequent hardening of the filler component can be provided to form a one-piece flux guidance unit. Hardening can achieve a certain bond strength between the filler component and the flux guidance element, which allows for easy handling of the one-piece flux guidance unit in a continuous manufacturing process. Handling can be improved by supporting auxiliary tools. Furthermore, the mechanical connection between adjacent flux guidance elements can be significantly enhanced by the targeted introduction of form-fitting contours (e.g., tongue-and-groove), further improving manageability.

[0163] The present invention further relates to a method for producing an inductive charging device according to the invention, wherein a coil is cast in the interior of a housing with a casting compound, wherein a flux guide element is arranged in an installation position relative to the coil and, for this purpose, is at least partially pressed into the casting compound, wherein the casting compound has an excess volume so that when the flux guide element is pressed into the casting compound, at least a part of the casting compound penetrates at least partially into a gap formed by two flux guide elements spaced apart from each other, wherein, after the flux guide element has been arranged in the installation position, at least one further layer of a filling component is introduced into the gap.

[0164] The coil can be cast in the protective housing using a magnetically neutral casting material without flux-guiding particles. The casting material can have good thermal conductivity. The casting material can have a thermal conductivity and / or thermal conductivity coefficient of at least 0.5 W / (mK), in particular at least 1.0 W / (mK), or in particular at least 10.0 W / (mK).

[0165] The castable is capable of forming a substantially magnetically neutral castable.

[0166] When the flux guiding element is pressed into the casting material, the casting material, in particular a magnetically neutral casting material, can penetrate or fill at least one gap, multiple gaps, or all gaps to approximately 5 to 20% of the gap height. Subsequently, one or more layers with flux guiding particles can be introduced into at least one gap, multiple gaps, or all gaps. The layer or layers with flux guiding particles can fill at least one gap, multiple gaps, or all gaps to approximately 50 to 90% of the gap height. The layer or layers can be introduced into the gap by distribution. The layer or layers can be introduced into at least one gap, multiple gaps, or all gaps as an adhesive layer and / or injection molding layer and / or a porous solid layer. The remaining gap space can be filled with the casting material, in particular a magnetically neutral casting material. In addition, the lateral surface of the magnetic field conductor facing away from the coil can be completely or partially covered and / or wetted by the casting material, in particular in a grid pattern. Here, the gap path can also be covered and / or wetted. Subsequently, a shielding shell, in particular in the form of a metal shielding sheet, can be placed or deposited on the casting material, in particular the allocated pattern. The shielding shell can then be pressed into the casting material to the desired distance from the flux guidance element relative to the coil winding axis. Subsequently, the device and / or the casting material and / or the filling component can be hardened, in particular thermally hardened.

[0167] The present invention also relates to a method for producing an inductive charging device according to the present invention, in which a filler component is introduced into a gap and subsequently compressed in the gap, in particular by hydraulic and / or pneumatic pressure. To this end, the structure of the flux guidance element, in particular the structure of the ferrite tiles, and the structure of the filler component can be positioned between two rubber bellows, wherein the pressure required for compression can be set. The elastic rubber material adapts to the gap contour and compresses the filler component in the gap. The filling height of the filler component in the gap can thereby be reduced. This method can also be used for fillers wrapped in paper.

[0168] Fillings, in particular compressed fillings, can be formed by a shaping method of ferrite powder, which is also used for the production (shaping) of green bodies in sintering processes.

[0169] To compress the flux guiding particles in the gap, a pressure of 1 MPa (e.g., loose compression) to 100 MPa (e.g., easily manageable independent green compacts) can be used. Preferably, to compress the flux guiding particles in the gap, a pressure of 10 to 20 MPa can be used, which is easily and economically manageable in terms of manufacturing technology and process.

[0170] Further important features and advantages of the invention emerge from the dependent claims, the drawings and the associated description of the figures with the aid of the drawings.

[0171] It is to be understood that the features mentioned above and the features yet to be explained further below can be used not only in the respectively indicated combination but also in other combinations or alone, without departing from the scope of the present invention. BRIEF DESCRIPTION OF THE DRAWINGS

[0172] Preferred exemplary embodiments of the invention are shown in the drawings and are explained in more detail in the following description, wherein identical reference numerals refer to identical or similar or functionally identical components.

[0173] Schematically shown respectively:

[0174] Figure 1 A cross-sectional view through an inductive charging device,

[0175] Figure 2 Figure 1 A magnified detail of

[0176] Figure 3 Cross-sectional view through an inductive charging device according to the invention,

[0177] Figure 4 A cross-sectional view through another inductive charging device according to the invention,

[0178] Figure 5A cross-sectional view through another inductive charging device according to the invention,

[0179] Figure 6 A cross-sectional view through another inductive charging device according to the invention,

[0180] Figure 7 A cross-sectional view through another inductive charging device according to the invention,

[0181] Figure 8 A cross-sectional view through another inductive charging device according to the invention,

[0182] Figure 9 A magnified detail of a gap filled by flux-guiding particles.

[0183] Figure 10 Vehicle charging system,

[0184] Figure 11 a vehicle for a vehicle charging system,

[0185] Figure 12 Top view of the gap between two flux guiding elements. DETAILED DESCRIPTION

[0186] Figure 1 Shown for Figure 10 Inductive charging device 1 of vehicle charging system 2 is shown.

[0187] Inductive charging device 1 can include a housing 10 formed of a protective shell 15 and a shielding shell 16. Housing 10 can form a housing interior 11 for accommodating components of inductive charging device 1. Protective shell 15 can be formed into a trough-shaped protective shell 15. Protective shell 15 can be formed of a non-conductive material. Shielding shell 16 can form a shield for electromagnetic shielding.

[0188] At least one coil 3 is arranged in the housing interior 11 , which coil is formed to generate or receive an alternating electromagnetic field. The coil 3 can be formed as a flat coil that can be wound substantially around a coil winding axis 20 .

[0189] Inductive charging device 1 includes a plurality of magnetic flux guidance elements 4 (specifically, 4a, 4b, 4c, and 4d) spaced apart from one another, arranged within housing interior 11. A gap 5, 5a is formed between two magnetic flux guidance elements 4, 4a and 4, 4b spaced apart from one another transversely to coil winding axis 20. A gap 5, 5b is formed between two magnetic flux guidance elements 4, 4b and 4, 4c spaced apart from one another transversely to coil winding axis 20. A gap 5, 5c is formed between two magnetic flux guidance elements 4, 4c and 4, 4d spaced apart from one another transversely to coil winding axis 20.

[0190] Figure 2The enlarged diagram shows Figure 1 Details of Figure 23. Figure 2 In FIG. 5 , the gap 5 , 5 b is explained by way of example, wherein the description also applies analogously to the other gaps 5 , 5 a and 5 , 5 c .

[0191] The gap 5 , 5 b has a gap height 21 and a gap width 22 . The gap height 21 is formed and / or oriented substantially parallel to the coil winding axis 20 . The gap width 22 is formed and / or oriented substantially transversely and / or perpendicularly to the coil winding axis 20 .

[0192] The gap width 22 corresponds essentially to the distance between the gap face 17b of the flux guidance element 4, 4b and the gap face 17c of the other flux guidance element 4, 4c, separated by the gap 5, 5b, transversely and / or perpendicularly to the coil winding axis 20. The gap faces 17b and 17c are oriented essentially parallel to the coil winding axis 20.

[0193] The gap height 21 corresponds to the thickness of the flux guidance elements 4, 4b and / or 4, 4c relative to the coil winding axis 20. The gap height 21 can correspond to the distance between the transverse surface 18b of the flux guidance elements 4, 4b facing away from the coil and the transverse surface 19b of the flux guidance elements 4, 4b facing toward the coil, relative to the coil winding axis 20. The gap height 21 can correspond to the distance between the transverse surface 18c of the flux guidance elements 4, 4c facing away from the coil and the transverse surface 19c of the flux guidance elements 4, 4c facing toward the coil, relative to the coil winding axis 20.

[0194] Transverse surfaces 19b and / or 19c facing the coil can be oriented substantially transversely and / or perpendicularly to the coil winding axis 20. Transverse surfaces 18b and / or 18c facing away from the coil can be oriented substantially transversely and / or perpendicularly to the coil winding axis 20.

[0195] The transverse surfaces 19b and 19c of the plurality of flux guidance elements 4, 4a and 4, 4b facing the coil can lie substantially in a common plane facing the coil and / or be oriented substantially therein. The transverse surfaces 18b and 18c of the plurality of flux guidance elements 4, 4a and 4, 4b facing away from the coil can lie substantially in a common plane facing away from the coil and / or be oriented substantially therein. The common plane facing the coil and the common plane facing away from the coil can be spaced apart from each other relative to the coil winding axis 20. The common plane facing the coil and the common plane facing away from the coil can be oriented substantially parallel to each other.

[0196] A plurality of or all magnetic field conductors 4 (particularly 4a, 4b, 4c and / or 4d) can have substantially the same thickness. A plurality of or all magnetic field conductors 4 (particularly 4a, 4b, 4c and / or 4d) can be similarly constructed.

[0197] In each of the gaps 5 (specifically, 5a, 5b and 5c), a filling component 6 (specifically, 6a, 6b and 6c) is at least partially provided. For the sake of clarity, the filling components 6 (specifically, 6a, 6b and 6c) are not shown in FIG. Figure 1 and Figure 2 is shown in Figures 3 to 9 Shown in. Figures 3 to 9 The structure of the inductive charging device 1 is Figure 1 The only difference is the construction of the filling assembly 6 (specifically, 6a, 6b and 6c), so that for components other than the filling assembly 6 (specifically, 6a, 6b and 6c), refer to the description of the filling assembly 6. Figure 1 Description.

[0198] exist Figure 3 , the gaps 5 (specifically, 5a, 5b, and 5c) are substantially completely filled with the filling components 6 (specifically, 6a, 6b, and 6c). The filling components 6 (specifically, 6a, 6b, and 6c) can form a layer 8 not shown.

[0199] For example, it can be provided that one or more or all layers are formed as a filling of flux-conducting particles, in particular a loose filling or a compressed filling. Layers (not shown) can be formed by gravity and / or by compression, wherein the number of magnetic field conductor particles or the density of the magnetic field conductor particles varies relative to the coil winding axis 20.

[0200] exist Figures 4 to 9 In each case, the filling components 6 , 6 b are explained by way of example, wherein this description also applies analogously to the other filling components 6 , 6 a and 6 , 6 c.

[0201] exist Figure 4 In the embodiment, the filling component 6, 6b has a plurality of layers 8. Layer 8, 8a is a magnetically conductive layer, which has, for example, flux-guiding particles. Layers 8, 8b and 8, 8c are formed as air layers. Layer 8, 8a can be formed from a plurality of layers, not shown.

[0202] exist Figure 5 In the embodiment, the filling component 6, 6b has a plurality of layers 8. Layer 8, 8a is a magnetically conductive layer, which has, for example, flux-guiding particles. Layers 8, 8b and 8, 8c are formed as magnetically neutral solid layers. Layer 8, 8a can be formed from a plurality of layers, not shown.

[0203] exist Figure 6In the embodiment, the filling components 6 and 6b have multiple layers 8. Layer 8 and 8a is a magnetically permeable layer containing, for example, flux guiding particles. Layers 8 and 8b and 8 and 8c are formed as magnetically neutral solid layers. Layer 8 and 8b also form an outer layer 9. Outer layer 9 integrally forms a spacer element for spacing the shielding shell 16 relative to the flux guiding elements 4 (specifically, 4a, 4b, 4c, and 4d). Layer 8 and 8a can be formed from multiple layers (not shown).

[0204] exist Figure 7 In the embodiment, the filling component 6, 6b has a plurality of layers 8. Layer 8, 8a is a magnetically conductive layer, which comprises, for example, flux-guiding particles. Layers 8, 8b and 8, 8c are formed as magnetically neutral solid layers. Layer 8, 8b is also formed as an outer layer 9. Figure 6 In contrast, the outer layers 9 of the filler components 6a, 6b, and 6c are directly connected to one another. The outer layers 9 of the filler components 6a, 6b, and 6c thus form a common outer layer that completely fills the free space between the shielding shell 16 and the flux guidance elements 4 (specifically, 4a, 4b, 4c, and 4d). This common outer layer can be formed, for example, from a casting compound, in particular a hardened casting compound.

[0205] exist Figure 8 In the embodiment, the filling components 6, 6b have a plurality of layers 8. Layer 8, 8a is a magnetically conductive layer, for example, comprising flux-guiding particles. Layers 8, 8b and 8, 8c are formed as magnetically neutral solid layers. Layers 8, 8b and 8, 8c also form an outer layer 9. The outer layers 9 of all filling components 6a, 6b, and 6c are directly connected to one another. The outer layers 9 of the filling components 6a, 6b, and 6c thus form a common outer layer that completely fills the shell interior 11.

[0206] For this purpose, the coil 3 can be cast in a protective shell 15, for example, with a neutral filler material, wherein the flux guidance elements 4 (specifically, 4a, 4b, 4c, and 4d) are subsequently inserted into the casting material. The flux guidance elements 4 (specifically, 4a, 4b, 4c, and 4d) can be used as an integrally mountable component, wherein the integrally mountable component can include parts or layers 8 of the filler component 6 (specifically, 6a, 6b, and 6c) before being inserted into the casting material.

[0207] The flux guidance elements 4 (specifically 4 a, 4 b, 4 c and 4 d) can also be inserted separately from one another into the casting compound, wherein the filling of the layer 8 of the respective filling component 6 is then carried out. The layers 8, 8 b, 9 can be formed by introducing further casting compound into the flux guidance elements 4 (specifically 4 a, 4 b, 4 c and 4 d) in order to completely fill the free space between the shielding shell 16 and the flux guidance elements 4 (specifically 4 a, 4 b, 4 c and 4 d).

[0208] exist Figure 9In the embodiment, the charging component 6, 6b has a plurality of layers 8. Layer 8, 8a is a magnetically conductive layer having flux-guiding particles 7. Layers 8, 8b and 8, 8c are formed as magnetically neutral solid layers. The flux-guiding particles 7 of layer 8, 8a have a particle shape that deviates from a spherical shape. These flux-guiding particles 7 of layer 8, 8a are oriented in the gaps 5, 5b so that they have a smaller extension in a direction parallel to the coil winding axis 20 than in a direction transverse to and / or perpendicular to the coil winding axis 20. This makes it possible to achieve a naturally oriented layer structure when introducing the flux-guiding particles 7 by dripping, pouring, or the like, or by an injection method for filling the matrix material, or by sedimentation in a low-viscosity suspension.

[0209] Figure 10 A vehicle charging system 2 is shown having a fixed inductive charging station 12 formed at least partially by an inductive charging device 1 according to the invention. The vehicle charging system 2 further comprises a mobile inductive device 14 attachable to a vehicle 13, the mobile inductive device being formed at least partially by an inductive charging device 1 according to the invention.

[0210] Figure 11 A vehicle 13 for vehicle charging system 2 is shown, which has a mobile inductive charging device 14 and a traction battery unit 24 which is electrically coupled to mobile inductive charging device 14 and can be supplied with electrical energy via the mobile inductive charging device.

[0211] Figure 12 A top view of gaps 5, 5b is shown, wherein the gap width 22 and gap length 25 of gaps 5, 5b are visible by way of example. In this illustration, the coil winding axis 20 is oriented perpendicular to the plane of the drawing. Filler elements 6, 6b, disposed in gaps 5, 5b, are formed from different material layers 26, 26a, and 26b relative to gap length 25, wherein layers 26 and 26b form magnetically neutral layers 27 and 27b (particularly air layers, respectively). Material layer 26a is at least partially or completely magnetically conductive. Material layer 26a can be formed from different layers 8 relative to gap height 21 (not shown).

Claims

1. An inductive charging device (1) for a vehicle charging system (2), - having at least one coil (3) for generating or receiving an alternating magnetic field, - having at least two flux guiding elements (4) spaced apart from one another, -in, At least one gap (5) is formed between two magnetic flux guiding elements (4) spaced apart from each other, -in, A filling assembly (6) is at least partially disposed in the gap (5), - wherein the filling component (6) is at least partially magnetically conductive, It is characterized in that - the filling component (6) has a plurality of layers (8), - at least one layer (8) of the filling component (6) forms a magnetically permeable layer (8a), and at least one layer (8) of the filling component (6) forms a magnetically neutral layer (8b, 8c), - each gap (5) has a gap height (21), a gap width (22), and a gap length (25), respectively, and The filling component (6) arranged in at least one gap (5) is formed from different layers (8a, 8b) with respect to the gap height (21) and / or with respect to the gap length (25).

2. The inductive charging device (1) according to claim 1, It is characterized in that The magnetically conductive layer (8a) of the filling component (6) has magnetic flux guiding particles (7), and / or - at least a portion of the flux guiding particles (7) are formed into a particle shape that deviates from a spherical shape, and / or - at least a portion of the magnetic flux guiding particles (7) are formed into a particle shape of a spheroid, and / or - at least a portion of the magnetic flux guiding particles (7) are formed into a particle shape of a triaxial ellipsoid, and / or - At least a portion of the magnetic flux guiding particles (7) are formed into a flat particle shape.

3. The inductive charging device (1) according to claim 2, It is characterized in that - at least a portion of the flux guiding particles (7) are introduced into the gap (5) as a filler, and / or - at least a portion of the flux guiding particles (7) are introduced into the gap (5) as a loose filler, and / or - At least a portion of the flux guiding particles (7) are introduced into the gap (5) as a compressed filler.

4. The inductive charging device (1) according to claim 3, It is characterized in that The filler is arranged in the gap (5) by means of a separate position fixing device, wherein the separate position fixing device is arranged in the gap (5) in a manner without a material connection to the magnetic flux guiding element (4) forming the gap, and / or The filler is arranged in the gap (5) by means of an integrated position fixation device, wherein the integrated position fixation device is at least partially connected in a materially bonded manner to the magnetic flux guidance element (4) forming the gap.

5. The inductive charging device (1) according to claim 4, It is characterized in that - the separation position fixing device has a housing for completely enclosing the magnetic flux guiding particles (7) of the filler, - wherein the shell together with the flux guiding particles (7) of the filler forms an encapsulation.

6. The inductive charging device (1) according to claim 4, It is characterized in that - the filler is arranged in the gap (5) by means of an integrated position fixing device to form a porous solid layer, - wherein the porous solid layer is formed by flux guiding particles (7) having a surface coating for materially connecting to each other and for at least partially materially connecting to the flux guiding element (4) forming the gap.

7. The inductive charging device (1) according to claim 2, It is characterized in that - the magnetically conductive layer (8a) of the filling component (6) has at least one embedding matrix for embedding the flux guiding particles (7), and / or - at least a portion of the flux guiding particles (7) are introduced as filler into at least one embedding matrix of the filling component (6), and / or - the embedding matrix with embedded flux guiding particles (7) is introduced into the gap (5) in the form of a paste, or - the embedding matrix with the embedded flux guiding particles (7) is introduced into the gap (5) in the form of a paste, wherein the embedding matrix is ​​formed by an actively hardenable matrix material, or The embedding matrix with the embedded flux guiding particles ( 7 ) is introduced into the gap ( 5 ) in the form of a paste, wherein the embedding matrix is ​​formed by a passively hardenable matrix material.

8. The inductive charging device (1) according to claim 7, It is characterized in that - an embedded matrix-forming foil element with embedded flux guiding particles (7), - wherein at least one such foil element is introduced into the gap (5).

9. The inductive charging device (1) according to any one of claims 1 to 8, Features: - at least one magnetically conductive layer (8a) of the filling component (6) is arranged between two magnetically neutral layers (8b, 8c) of the filling component (6), and / or The magnetically conductive layer (8a) of the filling component (6) is arranged to touch at least one magnetically neutral layer (8b, 8c) of the filling component (6).

10. The inductive charging device (1) according to any one of claims 1 to 8, It is characterized in that - at least one magnetically neutral layer (8b, 8c) of the filling component (6) is an air layer, and / or - at least one magnetically neutral layer (8b, 8c) of the packing element (6) is formed by a magnetically neutral solid layer, and / or The at least one magnetically neutral solid layer of the filling component (6) forms a magnetically neutral outer layer (9) which is formed at least partially inside the gap (5) and at least partially outside the gap (5).

11. The inductive charging device (1) according to any one of claims 1 to 8, It is characterized in that - forming at least two gaps (5a, 5b) spaced apart from each other, in which a filling component (6a, 6b) having at least one magnetic neutral layer (8b, 8c) is arranged, respectively, - wherein the magnetically neutral layers (8b, 8c) are connected to each other.

12. The inductive charging device (1) according to any one of claims 1 to 8, It is characterized in that - at least one layer (8) of the filling component (6) comprises flux guiding particles (7), and / or - at least one layer (8) of the filling component (6) comprises flux guiding particles (7), wherein within this layer (10) the concentration of the flux guiding particles (7) varies spatially, and / or At least two layers (8) of the filling component (6) each contain magnetic flux guiding particles (7), wherein the concentration of the magnetic flux guiding particles (7) is different in the two layers (10).

13. The inductive charging device (1) according to claim 10, It is characterized in that - at least one magnetically neutral solid layer of the filling component (6) is formed from a magnetically neutral casting material, and / or - the magnetically neutral outer layer (9) is formed for separating and / or connecting and / or fixing and / or positioning components of the inductive charging device (1), and / or The flux guidance elements (4) spaced apart from one another form together with the filling component (6) in the gap (5) an integrally mountable component.

14. The inductive charging device (1) according to claim 2, It is characterized in that - The flat particle shape is a lens-shaped or plate-shaped particle shape.

15. The inductive charging device (1) according to any one of claims 4 to 6, It is characterized in that - The filling is a loose fill and / or a compressed fill.

16. The inductive charging device (1) according to claim 5, It is characterized in that - The shell is a shell of paper material.

17. The inductive charging device (1) according to claim 7, It is characterized in that - the actively hardenable matrix material is a binder material, or The passively hardenable matrix material is a thermoplastic material and / or a thermosetting material and / or an elastomer and / or a hydraulic material.

18. The inductive charging device (1) according to claim 13, It is characterized in that - The at least one magnetically neutral solid layer is a magnetically neutral outer layer (9).

19. The inductive charging device (1) according to any one of claims 1 to 8, It is characterized in that the inductive charging device (1) has more than two flux conducting elements (4) spaced apart from one another, wherein a plurality of gaps (5) are formed between the flux guiding elements (4) spaced apart from one another, - wherein a filling component (6) is at least partially arranged in only a part of the gaps (5).

20. A device for a flux conducting element (4) of an inductive charging device (1) according to one of the preceding claims, - having at least two flux guiding elements (4) spaced apart from one another, -in, At least one gap (5) is formed between the two flux guiding elements (4) spaced apart from each other, - wherein the gap (5) is partially or completely filled with a filling component (6) having a plurality of layers (8), - wherein the magnetic flux guidance elements (4) spaced apart from one another together with the filling component (6) in the gap (5) form an integrally mountable component.

21. A vehicle charging system (2), - a stationary inductive charging station (12) which is formed at least partially by an inductive charging device (1) according to one of claims 1 to 19, and / or A mobile inductive charging device (14) attachable to a vehicle (13) and at least partially formed by an inductive charging device (1) according to one of claims 1 to 19.

Images