A horizontally arranged wireless charging battery box

Abstract

The application belongs to the technical field of battery boxes, and provides a horizontally-arranged wireless charging battery box, characterized in that the wireless charging battery box comprises a tray part, a frame part, a bottom guard plate, a wireless receiver rectifier and a wireless receiver coil module; the frame part is connected around the tray part, and the bottom guard plate is installed at the lower part of the tray part; the wireless receiver coil module and the wireless receiver rectifier are arranged in the bottom guard plate; the wireless receiver rectifier is electrically connected with the wireless receiver coil module through a wire harness; and the wireless receiver coil module and the wireless receiver rectifier are arranged in a horizontal direction in the battery box. The application has the advantages that the receiving end module of wireless charging is integrated, the cost of the wireless charging module is reduced through the integration of the wireless charging module and the battery box, a wider installation space is provided, and the added value of the battery box is improved.

Description

Technical Field

[0001] This invention belongs to the field of battery box technology and relates to a horizontally arranged wireless charging battery box. Background Technology

[0002] To conserve energy and reduce environmental pollution, electric vehicles have been vigorously promoted worldwide. However, due to limitations in battery capacity and charging infrastructure, charging has become the most significant bottleneck in the development of electric vehicles. Wireless charging technology, which addresses interface limitations and safety issues associated with traditional conductive charging, has gradually become the primary charging method for electric vehicles. However, static wireless charging, like wired charging, suffers from frequent charging, short driving range, large battery consumption, and high costs. This is particularly critical for public transportation vehicles such as electric buses, where continuous driving range is extremely important. Against this backdrop, dynamic wireless charging technology for electric vehicles has emerged, providing real-time energy supply to electric vehicles in motion through a contactless method.

[0003] Wireless charging technology for electric vehicles transmits electrical energy to a receiving mechanism on the ground within a certain range via a high-frequency alternating magnetic field through a power rail buried underground. This energy then powers the onboard energy storage device, allowing electric vehicles to carry fewer battery packs, extending their driving range, while making energy replenishment safer and more convenient. The main parameters of dynamic wireless power supply technology include power transmission distance, power, efficiency, lateral displacement adaptability of the coupling mechanism, and electromagnetic compatibility. Therefore, developing a high-power, high-efficiency, highly adaptable, low-electromagnetic-radiation, and cost-effective dynamic wireless power supply system has become a major research focus for research institutions both domestically and internationally.

[0004] The development of the new energy industry, especially the rapid growth of pure electric vehicles, will inevitably place higher demands on the diversification and convenience of electric vehicle charging methods. Wireless charging technology, as an emerging technology, is mainly used commercially for charging low-power devices such as mobile phones, computers, and portable music players; it is still a completely new concept in the electric vehicle field. With the maturation of wireless charging technology, electric vehicles will be the most promising market for wireless charging equipment. Currently, most automotive wireless receivers are installed in the front subframe, which has significant space limitations, especially regarding the coil installation area. For future applications requiring higher power and larger coils, the space limitations will be even greater. Furthermore, the casing of automotive wireless receivers, especially the coil tray, is mostly made of plastic, which has poor impact resistance. Summary of the Invention

[0005] The technical problem to be solved by the present invention is to provide a horizontally arranged wireless charging battery box that integrates the wireless charging receiver into the battery box, thereby making full use of the wide design space in the XY direction of the battery box and greatly improving the added value of the new energy battery box.

[0006] The technical solution adopted by the present invention to solve the above-mentioned technical problems is as follows: a horizontally arranged wireless charging battery box, characterized in that it includes a tray, a frame, a bottom cover, a wireless receiver rectifier, and a wireless receiver coil module. The frame is connected around the tray, the bottom cover is installed at the bottom of the tray, and the wireless receiver coil module and the wireless receiver rectifier are both arranged in the bottom cover. The wireless receiver rectifier is electrically connected to the wireless receiver coil module through a wire harness, and the wireless receiver coil module and the wireless receiver rectifier are arranged horizontally in the battery box.

[0007] In the aforementioned horizontally arranged wireless charging battery box, the wireless receiver coil module includes a coil tray, a coil, a ferrite, and a wireless charging water-cooling plate. The coil is located inside the coil tray, the ferrite is located above the coil, and the wireless charging water-cooling plate covers the upper part of the coil tray with thermally conductive adhesive filling the space between them. The integrated module consisting of the coil tray, coil, ferrite, and wireless charging water-cooling plate is installed between the bottom protective plate and one side of the tray.

[0008] In the aforementioned horizontally arranged wireless charging battery box, the wireless receiver rectifier is installed between the bottom protective plate and the other side of the tray component, and thermally conductive adhesive is poured between the wireless receiver rectifier, the wireless charging water-cooling plate, and the tray component.

[0009] In one of the horizontally arranged wireless charging battery cases described above, the bottom cover has a receiving slot for placing the wireless receiver coil module and the wireless receiver rectifier.

[0010] As a second approach, in the aforementioned horizontally arranged wireless charging battery box, a tray water-cooling plate is connected to the lower surface of the tray component, and the wireless receiver coil module is installed between the lower part of the tray water-cooling plate and the bottom protective plate.

[0011] In the aforementioned horizontally arranged wireless charging battery box, the wireless receiver coil module includes a coil tray, a coil, and a ferrite. The coil is located inside the coil tray, the ferrite is located above the coil, and the tray water-cooling plate is located above the wireless receiver coil module. Thermally conductive adhesive is filled between the wireless receiver coil module, the tray, and the tray water-cooling plate. The integrated module consisting of the coil tray, the coil, the ferrite, and the wireless charging water-cooling plate is installed between the bottom protective plate and one side of the tray. The wireless receiver rectifier is installed between the bottom protective plate and the other side of the tray. Thermally conductive adhesive is filled between the wireless receiver rectifier and the wireless charging water-cooling plate and the tray.

[0012] In the aforementioned horizontally arranged wireless charging battery box, EPDM sealing gaskets are provided on both sides of the coil tray and the tray component.

[0013] As a third approach, in the aforementioned horizontally arranged wireless charging battery box, a tray water-cooling plate is connected to the lower surface of the tray component, and the wireless receiver coil module is installed between the lower part of the tray water-cooling plate and the bottom protective plate.

[0014] In the aforementioned horizontally arranged wireless charging battery box, the wireless receiver coil module includes a coil and a ferrite core. The coil is embedded in the bottom protective plate, the ferrite core is located above the coil, and the tray water-cooling plate is located above the wireless receiver coil module. Thermally conductive adhesive is filled between the wireless receiver coil module, the bottom protective plate, and the tray water-cooling plate. The integrated module consisting of the coil, ferrite core, and wireless charging water-cooling plate is installed between the bottom protective plate and one side of the tray component. The wireless receiver rectifier is installed between the bottom protective plate and the other side of the tray component. Thermally conductive adhesive is filled between the wireless receiver rectifier, the wireless charging water-cooling plate, and the tray component.

[0015] In the aforementioned horizontally arranged wireless charging battery box, EPDM sealing gaskets are provided on both sides of the coil and the tray.

[0016] Compared with existing technologies, the advantages of this invention lie in integrating the wireless charging receiver into the battery box and adopting a horizontal arrangement, which greatly enhances the added value of the new energy battery box. In terms of cooling, this patent utilizes a brazed water-cooled plate in conjunction with the battery box, simultaneously cooling the heat of the battery cell module and the wireless receiver coil module. Structurally, the composite material bottom plate of the battery box not only provides strength but also serves as a mounting carrier for the wireless receiver coil module. Therefore, for most brazed water-cooled plate battery boxes, only the composite material bottom plate needs to be replaced, resulting in high overall structural compatibility. In terms of cost, omitting the wireless charging module housing and water cooling significantly reduces costs. By integrating the wireless receiver and battery box, this invention not only reduces the cost of the wireless charging module and provides ample installation space but also increases the added value of the battery box. Attached Figure Description

[0017] Figure 1 This is a schematic diagram of the modular integrated exploded structure of this horizontally arranged wireless charging battery box.

[0018] Figure 2 yes Figure 1 Schematic diagram of the cross-sectional structure after assembly;

[0019] Figure 3 yes Figure 1 A schematic diagram of the structure of the wireless receiver coil module in the diagram;

[0020] Figure 4 This is a schematic diagram of the non-embedded integrated structure of the coil of this horizontally arranged wireless charging battery box.

[0021] Figure 5 yes Figure 4 Schematic diagram of the cross-sectional structure after assembly;

[0022] Figure 6 yes Figure 4 A schematic diagram of the structure of the wireless receiver coil module in the diagram;

[0023] Figure 7 This is a schematic diagram of the coil-embedded integrated exploded structure of this horizontally arranged wireless charging battery box.

[0024] Figure 8 yes Figure 7 Schematic diagram of the cross-sectional structure after assembly;

[0025] Figure 9 yes Figure 7 A schematic diagram of the structure of the wireless receiver coil module. Detailed Implementation

[0026] The technical solutions in the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only a part of the embodiments of the present invention, and not all of them. All other embodiments obtained by those skilled in the art based on the embodiments of the present invention without creative effort are within the scope of protection of the present invention.

[0027] In the description of this invention, it should be understood that the terms "center," "lateral," "longitudinal," "front," "rear," "left," "right," "upper," "lower," "vertical," "horizontal," "top," "bottom," "inner," and "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 limiting the scope of protection of this invention.

[0028] In the figure, tray component 100; frame component 200; bottom protective plate 300; receiving slot 301; wireless receiver rectifier 400; wireless receiver coil module 500; coil tray 501; coil 502; ferrite 503; wireless charging water cooling plate 504; thermally conductive adhesive 600; EPDM sealing gasket 700; tray water cooling plate 800.

[0029] Example 1

[0030] like Figure 1As shown, this horizontally arranged wireless charging battery box includes a tray 100, a frame 200, a bottom cover 300, a wireless receiver rectifier 400, and a wireless receiver coil module 500. The frame 200 is connected around the tray 100, and the bottom cover 300 is installed at the bottom of the tray 100. The bottom cover 300 can be made of composite material. The wireless receiver coil module 500 and the wireless receiver rectifier 400 are both arranged in the bottom cover 300. The wireless receiver rectifier 400 is electrically connected to the wireless receiver coil module 500 via a wiring harness. The wireless receiver coil module 500 and the wireless receiver rectifier 400 are arranged horizontally in the battery box. This patent achieves wireless charging mainly through wireless... The system consists of a receiver rectifier 400 and a wireless receiver coil module 500. The wireless receiver coil module 500 receives the magnetic field lines from the ground transmitter and generates electrical energy. After voltage adjustment by the rectifier, the electrical energy is transmitted to the BMS electronic control system of the battery box in the form of DC power. The overall arrangement is horizontal in the battery box, that is, both the wireless receiver coil module 500 and the wireless receiver rectifier 400 are arranged in the bottom protective plate 300. According to the different integration levels from low to high, the horizontal direction of this patent can be further subdivided into the following three types: modular integration, non-embedded coil integration, and embedded coil integration. Whether the tray 100 of the battery box module is integrated with water cooling determines whether the module and the wireless receiver coil module 500 can share the water cooling system.

[0031] Regarding modular integration methods, such as Figure 2 and Figure 3As shown, the wireless receiver coil module 500 includes a coil tray 501, a coil 502, a ferrite core 503, and a wireless charging water-cooling plate 504. The coil 502 is located inside the coil tray 501, the ferrite core 503 is located above the coil 502, and the wireless charging water-cooling plate 504 covers the coil tray 501 with thermally conductive adhesive 600 filling the space between them. The thermally conductive adhesive 600 mainly serves the dual functions of connection and heat conduction. The integrated module consisting of the coil tray 501, coil 502, ferrite core 503, and wireless charging water-cooling plate 504 is installed between the bottom protective plate 300 and one side of the tray component 100. The wireless receiver rectifier 400 is installed between the bottom protective plate 300 and the other side of the tray component 100. The wireless receiver rectifier 400 and the wireless charging water-cooling plate 504... Thermally conductive adhesive 600 is filled between the tray components 100. It can be seen that the wireless receiver rectifier 400 and the wireless receiver coil module 500 are located on the horizontal sides of the battery box respectively. The bottom protective plate 300 has a receiving groove 301 for placing the wireless receiver coil module 500 and the wireless receiver rectifier 400. Here, this patent reserves installation space for the wireless receiver coil module 500 on the bottom protective plate 300. After the wireless receiver coil module 500 is assembled as a small assembly, its coil tray 501 is separately glued to the bottom protective plate 300. Since the tray component 100 of the battery box itself does not integrate water cooling, the wireless receiver coil module 500 still has its own wireless charging water cooling plate 504. The cooling water source for the wireless charging water cooling plate 504 is provided by the battery box.

[0032] Example 2

[0033] For non-embedded coil integration methods, such as Figure 4 , Figure 5 as well as Figure 6As shown, a tray water-cooling plate 800 is connected to the lower surface of the tray 100. The wireless receiver coil module 500 is installed between the lower part of the tray water-cooling plate 800 and the bottom protective plate 300. The wireless receiver coil module 500 includes a coil tray 501, a coil 502, and a ferrite 503. The coil 502 is located inside the coil tray 501, and the ferrite 503 is located above the coil 502. The tray water-cooling plate 800 is located above the wireless receiver coil module 500. Thermally conductive adhesive 600 is filled between the wireless receiver coil module 500, the tray 100, and the tray water-cooling plate 800. EPDM sealing gaskets 700 are provided on both sides of the coil tray 501 and the tray 100. Here, the EPDM sealing gaskets 700 can ensure the sealing performance on both sides. In this embodiment, the non-embedded type means that the coil is not embedded in the bottom protective plate 300. This integration scheme still retains the coil tray 501 of the wireless receiver coil module 500. 1. The coil tray 501 is glued to the bottom cover plate 300, but the original wireless charging water cooling plate 504 on the top is replaced by the battery box tray water cooling plate 800. Here, the tray water cooling plate 800 can be a brazed water cooling plate, that is, the battery box module and the wireless receiver coil module 500 share a tray water cooling plate 800 for cooling. The wireless receiver rectifier 400 and the wireless receiver coil module 500 are connected by a wire harness, and both use the battery box tray water cooling plate 800 for cooling. The integrated module consisting of the coil tray 501, coil 502, ferrite 503 and tray water cooling plate 800 is installed between the bottom cover plate 300 and the tray component 100 on one side. The wireless receiver rectifier 400 is installed between the bottom cover plate 300 and the tray component 100 on the other side. Thermally conductive adhesive 600 is poured between the wireless receiver rectifier 400 and the tray water cooling plate 800 and the tray component 100.

[0034] Example 3

[0035] For coil-embedded integration methods, such as Figure 7 , Figure 8 as well as Figure 9As shown, a tray water-cooling plate 800 is connected to the lower surface of the tray component 100. A wireless receiver coil module 500 is installed between the lower part of the tray water-cooling plate 800 and the bottom protective plate 300. The wireless receiver coil module 500 includes a coil 502 and a ferrite 503. The coil 502 is embedded in the bottom protective plate 300, and the ferrite 503 is located above the coil 502. The tray water-cooling plate 800 is located above the wireless receiver coil module 500. Thermally conductive adhesive 600 is applied between the bottom protective plate 300 and the tray water-cooling plate 800. EPDM sealing gaskets 700 are provided on both sides of the coil 502 and the tray component 100. The embedded type means that the coil 502 is embedded in the bottom protective plate 300. During the molding process of the bottom protective plate 300, the coil 502 is also embedded into the bottom protective plate 300 and integrally molded. This integrated solution not only eliminates the coil tray 501 of the wireless receiver coil module 500, but also eliminates the built-in wireless charging water-cooling plate on top. 504 replaces the battery box's tray water-cooling plate 800 for cooling. That is, the battery box module and the wireless receiver coil module 500 share a tray water-cooling plate 800 for cooling. The integrated module consisting of coil 502 and ferrite 503 is installed between the bottom protective plate 300 and one side of the tray component 100. The wireless receiver rectifier 400 is installed between the bottom protective plate 300 and the tray component 100 on the other side. Thermally conductive adhesive 600 is poured between the wireless receiver rectifier 400 and the tray water-cooling plate 800 and the tray component 100. In other words, the wireless receiver rectifier 400 and the wireless receiver coil module 500 are horizontally arranged and share the bottom protective plate 300 and the tray water-cooling plate 800. The wireless receiver rectifier 400 and the wireless receiver coil module 500 are connected by a wire harness and both use the battery box's tray water-cooling plate 800 for cooling. While utilizing the strength performance of the bottom protective plate 300, it can also serve as a mounting carrier for the wireless receiver coil module 500. Therefore, for most brazed water-cooled plate battery boxes, simply replacing the bottom protective plate with a composite material 300 results in high overall structural compatibility. In terms of cost, omitting the housing of the wireless charging module and water cooling significantly reduces the cost.

[0036] In summary, by leveraging the advantages of the 300 high-strength battery box bottom cover plate, which can be complexly molded and is free from magnetic field interference, a wireless charging receiver module is integrated. By integrating the wireless charging module and the battery box, the cost of the wireless charging module is reduced, a wider installation space is provided, and the added value of the battery box is increased.

[0037] The specific embodiments described herein are merely illustrative examples illustrating the spirit of the invention. Those skilled in the art to which this invention pertains may make various modifications or additions to the described specific embodiments or use similar methods to substitute them, without departing from the scope defined by the spirit of the invention.

Claims

1. A horizontally arranged wireless charging battery box, characterized by, The device includes a tray, a frame, a bottom cover, a wireless receiver rectifier, and a wireless receiver coil module. The frame is connected around the perimeter of the tray, and the bottom cover is installed at the bottom of the tray. The wireless receiver coil module and the wireless receiver rectifier are both housed within the bottom cover. The wireless receiver rectifier is electrically connected to the wireless receiver coil module via a wiring harness, and both are arranged horizontally within the battery compartment. A tray water-cooling plate is attached to the lower surface of the tray, and the wireless receiver coil module is mounted on the tray water-cooling plate. Between the lower part of the plate and the bottom protective plate; the wireless receiver coil module includes a coil and a ferrite. The coil is embedded in the bottom protective plate, the ferrite is located above the coil, and the tray water-cooling plate is located above the wireless receiver coil module. Thermally conductive adhesive is filled between the wireless receiver coil module, the bottom protective plate, and the tray water-cooling plate. The integrated module consisting of the coil and the ferrite is installed between the bottom protective plate and one side of the tray component. The wireless receiver rectifier is installed between the bottom protective plate and the other side of the tray component. Thermally conductive adhesive is filled between the wireless receiver rectifier and the tray water-cooling plate and the tray component.

2. A horizontally arranged wireless charging battery box according to claim 1, characterized in that, EPDM sealing gaskets are provided on both sides of the coil and the tray component.

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