Power converter assembly

Abstract

The present invention relates to a wireless charger for charging a high voltage (HV) battery of a vehicle, comprising: a coil configured to wirelessly receive an oscillating magnetic field from an external transmitter, thereby generating an alternating current (AC); a ferrite disposed adjacent to the coil; a cooling channel disposed adjacent to at least one of the ferrite and the coil, the cooling channel configured to provide a flow of coolant; an electrical component configured for charging the HV battery based on AC; a metal cover separating the coil and the ferrite from the electrical components, at least one of the electrical components being disposed adjacent to the metal cover, where the wireless charger further includes a non-conductive portion configured to at least partially form a cooling channel and to separate the coil and the ferrite from the metal cover.

Description

Technical Field

[0001] The present invention relates to a power converter assembly for converting the electromagnetic power of an oscillating electromagnetic field into electric power of current or available current for charging an electric storage device or exciting an electric load. The power converter assembly includes a magnetic assembly for receiving the oscillating electromagnetic field and converting it into an alternating current, and an electronic assembly for receiving the alternating current and converting it into an electric current or available current. The power converter assembly further includes a heat sink for dissipating the heat generated by the electronic assembly during its corresponding power conversion operation.

[0002] A power converter assembly (also called a wireless charger module) can be used to charge a vehicle's high-voltage (HV) battery. Such a module (sometimes also called a car-pad module (CPM)) can receive an oscillating magnetic field from an external transmitter (sometimes called a ground-pad module (GPM)) and transform the oscillating electromagnetic field (mainly a magnetic field) into an alternating current, which is converted (usually rectified) into a current (usually a direct current) for charging the HV battery. Background Art

[0003] The battery of an electric vehicle can be charged using either alternating current (AC) or direct current (DC) energy transfer. DC energy transfer is usually provided using a high-power converter placed at a dedicated charging point. Although DC charging is usually faster than AC charging, it is not as convenient for the end user because it is expensive to install DC charging points and the existing network capacity in houses or residential areas is often fragile, so DC charging points are usually placed in remote areas rather than installed in houses or residential areas.

[0004] On the other hand, AC charging is very important for residential areas and (semi) public urban areas. A typical AC charger is able to provide a charging power of up to 22kW. AC charging systems can be divided into wired charging systems and wireless charging systems, among which wireless charging systems are mainly embodied as inductive charging systems (ICS). Wired AC chargers are typically integrated into electric vehicles and are also referred to as on-board chargers. ICS typically includes two separate modules, often referred to as ground pad modules (GPM) and car pad modules (CPM).

[0005] The GPM is mounted on the outside of the electric vehicle, while the CPM is mounted on the inside of the electric vehicle, typically on the underside of the vehicle. The electromagnetic interaction between the GPM and the CPM causes energy to be transferred from the GPM to the CPM, and the CPM is in turn used to charge the battery of the electric vehicle. Wireless charging systems are generally more convenient for users because, other than parking the vehicle on the GPM, no manual intervention is typically required to initiate the charging process of the battery. Wired charging systems, on the other hand, require the user to connect the electric vehicle to the utility grid via a cable.

[0006] The term "GPM" as used herein should be understood to be equivalent to the term "wireless charging supply" or simply "supply" as used herein. The term "CPM" as used herein should be understood to be equivalent to the term "wireless charger" or simply "charger" as used herein. In addition, in this document, the terms "power converter assembly" and "wireless charger" or "wireless charger module" are used interchangeably.

[0007] When it comes to cooling, it is important to understand that a CPM has two heat generating areas: (a) the electronic components (power electronics), which generate a lot of heat but are relatively concentrated at specific locations (high density), and (b) the magnetic components (coils and ferrites), which generate less and better distributed heat (low density). Prior art cooling systems for such CPMs are not well adapted to these conditions and are difficult and therefore expensive to manufacture. Summary of the invention

[0008] Purpose of the invention

[0009] It is therefore an object of the present invention to provide a power converter assembly which meets the overall cooling requirements, and in particular the electronic assembly cooling requirements, and which can be manufactured easily and at relatively low cost.

[0010] Summary of the Invention

[0011] This object is achieved by a power converter assembly for converting the electromagnetic power of an oscillating electromagnetic field into electrical power for charging an electrical storage device or exciting an electrical load, the power converter assembly comprising:

[0012] a magnetic assembly for receiving the oscillating electromagnetic field and converting it into an alternating current;

[0013] An electronic component for receiving an alternating current and converting it into an electric current, wherein

[0014] The power converter assembly includes a heat sink for dissipating heat generated by the magnetic and electronic components during their respective power conversion operations, characterized in that:

[0015] a) the heat sink is arranged between the magnetic component and the electronic component and is in thermal contact with the magnetic component and the electronic component;

[0016] b) a heat dissipation device, comprising:

[0017] a first portion in thermal contact with the magnetic assembly, and

[0018] a second portion in thermal contact with the electronic component;

[0019] c) the first portion comprises a first material and / or has a first structure suitable for dissipating heat flow from the magnetic component;

[0020] d) The second portion comprises a second material different from the first material and / or has a second structure different from the first structure, the second structure being suitable for dissipating heat flow from the electronic component.

[0021] Therefore, a first portion of a first material and / or a first structure that is in thermal contact with the magnetic component and that includes a first material and / or a first structure that is suitable for dissipating heat flow from the magnetic component provides a first portion of overall heat dissipation from the power converter component. Similarly, a second portion of a second material that is in thermal contact with the electronic component and that includes a second material different from the first material and / or a second structure that is different from the first structure that is suitable for dissipating heat flow from the electronic component provides a second portion of overall heat dissipation from the power converter component.

[0022] In other words, in a case where the magnetic component in the power converter assembly is a first type of heat source and the electronic component is a second type of heat source, the present invention achieves heat source specific heat dissipation by providing a first part as a first type of heat sink and a second part as a second type of heat sink. By allowing the materials and / or structures of the first part (first type of heat sink) and the second part (second type of heat sink) to be different from each other, each of the first part and the second part needs to meet the heat dissipation requirements of the magnetic component (first type of heat source) and the electronic component (second type of heat source), respectively.

[0023] Thus, the first part can be provided with only a first material and a first structure that primarily meets the heat dissipation requirements of the magnetic component, and the second part can be provided with only a second material and a second structure that primarily meets the heat dissipation requirements of the electronic component. Thus, the specific heat dissipation requirements for each of the first and second parts can be minimized, which allows significant savings to be achieved. For example, savings can be achieved by selecting a material with low thermal conductivity, and the low thermal conductivity can be compensated by providing the material with a special structure that helps to improve the heat flow.

[0024] The invention further facilitates more design flexibility of the power converter and a reduction in the parts involved.

[0025] Preferably, the first portion comprises a first material having a first thermal conductivity, and the second portion comprises a second material having a second thermal conductivity, the second thermal conductivity being greater than the first thermal conductivity.

[0026] Preferably, the thermal conductivity of the second material is greater than 100 W / (m·K). This ensures sufficient heat flow from the electronic component which is a heat source with concentrated hot spots and relatively high temperatures.

[0027] Preferably, the first material and / or the second material is a metal, a metal alloy, a polymer, a polymer blend or a composite* material.

[0028] Preferably, the first material is a polymer or a polymer blend.

[0029] Preferably, the second material is a metal, a metal alloy or a composite material.

[0030] In a preferred embodiment, the first part comprises a portion defining a conduit for a heat transfer fluid (coolant).This allows the first part to be arranged in fluid connection with a coolant circuit, wherein the conduit of the first part is preferably part of the coolant circuit.

[0031] Preferably, the first part with said duct defining portion is made by forming (shaping) the material in a mould. This allows reducing manufacturing costs.

[0032] The first portion having the duct-defining portion may be made by molding (casting, injecting) a moldable material in the mold.

[0033] The first portion having the duct defining portion may be formed by sintering a sinterable material within the mould.

[0034] The first portion having the duct-defining portion may be manufactured by cross-linking a cross-linkable material within the mold.

[0035] Preferably, the first part with the conduit defining portion is manufactured in an additive layer-by-layer manner. This allows manufacturing of complex geometries of the first part that facilitate efficient heat transfer from the magnetic components (coils, ferrites) as a more evenly distributed heat source to the first part as a heat sink with a heat transfer fluid (coolant) flowing through the conduit.

[0036] Preferably, the first part comprises a polymer. This allows the first part with its duct geometry to be manufactured by low-cost molding.

[0037] The first part may comprise a polymer matrix in which particles are dispersed, the particles being selected from the group comprising metal particles and graphite particles. These particles increase the electrical conductivity of the polymer.

[0038] Preferably, the second part comprises a solid metal material. This ensures sufficient heat flow from the electronic components as heat sources with concentrated hot spots and relatively high temperatures. In addition, it provides additional mechanical strength for the entire dissipation device.

[0039] Preferably, the second part comprises a porous metal material. This allows reducing the amount of metal material required without significantly reducing the thermal conductivity and mechanical strength of the second part. Thus, weight and material costs can be reduced relative to solid metal materials.

[0040] In a preferred embodiment, the second portion comprises a metal layer. The metal layer helps to homogenize local temperature peaks / hot spots of the electronic component by heat flow in a lateral direction along the metal layer.

[0041] Preferably, the magnetic assembly comprises a coil.

[0042] Preferably, the magnetic assembly comprises a material adjacent the coil, said material having a magnetic permeability greater than or equal to one.

[0043] Preferably, the material adjacent the coil is ferrite.

[0044] Preferably, the electronic assembly comprises a power electronics part.

[0045] Preferably, the heat sink comprises a third portion arranged between the first portion and the magnetic assembly. As previously mentioned, the first portion may be provided with only a first material and a first structure that primarily meet the heat dissipation requirements of the magnetic assembly, and the second portion may be provided with only a second material and a second structure that primarily meet the heat dissipation requirements of the electronic assembly. With the third portion, the overall heat dissipation characteristics provided by the first and second portions may be further modified. In addition, each of the three portions may have its own material and geometry.

[0046] Therefore, the overall heat dissipation device of the power converter assembly or the wireless charger according to the present invention can be assembled with two or three heat dissipation parts in a modular manner to obtain specific heat dissipation and mechanical properties of the entire heat dissipation device.

[0047] Preferably, the third part comprises a solid metal material. This ensures sufficient heat flow from the magnetic assembly. Also, it provides additional mechanical strength to the entire dissipation device.

[0048] Preferably, the third part comprises a porous metal material. Again, this allows reducing the amount of metal material required without significantly reducing the thermal conductivity and mechanical strength of the third part. Thus, weight and material costs can be reduced relative to solid metal materials.

[0049] Preferably, the third portion comprises a metal layer. Again, the metal layer helps to homogenize any local temperature inhomogeneities of the magnetic assembly by heat flow in a lateral direction along the metal layer.

[0050] Preferably, the three-part sandwich arrangement consisting of the first part, the second part and the third part is arranged between the magnetic component and the electronic component, and is in thermal contact with each of them. The three-part sandwich arrangement consisting of the first, second and third parts defined above helps to improve the mechanical strength of the sandwich type integral heat dissipation device. Preferably, the sandwich structure is arranged between the magnetic component (first heat source) and the electronic component (second heat source), and is in thermal contact with each of them.

[0051] Preferably, the second and third parts have a higher mechanical strength than the first part between the two of them. This provides an overall heat sink with high bending stiffness. Preferably, the second and third parts are made of solid or porous metal layers, while the first part between them can be made of a polymer. The first part can be a web structure, preferably a perforated honeycomb structure, allowing coolant flow while providing high bending stiffness with less weight.

[0052] Preferably, the conduit for the heat transfer fluid defined by the material of the first portion includes a plurality of flow obstructions extending across the conduit.

[0053] At least some of the flow obstructions may be integrally formed with the first portion.

[0054] At least some of the flow obstructions may be integrally formed with the second portion.

[0055] At least some of the flow obstructions may be integrally formed with the third portion.

[0056] Preferably, the first portion comprises a functional portion formed integrally with the duct defining material of the first portion.

[0057] These functional parts may include at least one of a heat transfer fluid (coolant) inlet, a heat transfer fluid (coolant) outlet, a vent tube (breathing element), and an interface structure.

[0058] For example, the present invention relates to a wireless charger for charging a high voltage (HV) battery of a vehicle, comprising: a coil configured to wirelessly receive an oscillating magnetic field from an external transmitter, thereby generating an alternating current; a ferrite arranged adjacent to the coil; a cooling channel arranged adjacent to at least one of the ferrite and the coil, the cooling channel configured to provide a coolant flow; an electrical component configured to charge the HV battery based on AC; a metal cover separating the coil and the ferrite from the electrical component, at least one of the electrical components being arranged adjacent to the metal cover, wherein the wireless charger further comprises a non-conductive portion configured to at least partially form the cooling channel and separate the coil and the ferrite from the metal cover.

[0059] In some embodiments, the cooling channels are at least partially formed by recesses machined or formed in the non-conductive portion.

[0060] In some embodiments, the cooling channel is formed by the metal cover closing the recess by abutting the non-conductive portion.

[0061] In some embodiments, the wireless charger further includes a plate, wherein the cooling channel is formed by the plate closing the recess by abutting the non-conductive portion, the plate separating the non-conductive portion from the metal cover.

[0062] In some embodiments, the cooling channels are incorporated into the non-conductive portion.

[0063] In some embodiments, the metal cover is at least a portion of a housing of the HV battery.

[0064] In some embodiments, the metal cover includes a structure for enlarging the heat sink, which is immersed in the cooling channel.

[0065] In some embodiments, the wireless charger further includes a coolant inlet and a coolant outlet, both of which are machined or formed as non-conductive portions.

[0066] In some embodiments, the metal cover is glued to the non-conductive portion.

[0067] In some embodiments, the metal cover is planar at least in an area adjacent to the non-conductive portion.

[0068] In some embodiments, the non-conductive portion is made of plastic.

[0069] In some embodiments, the coil and ferrite are combined in one potting.

[0070] In some embodiments, the wireless charger further includes a coil cover made of plastic, the potting is embedded in the coil cover, and the coil cover is configured to engage with the non-conductive portion.

[0071] In some embodiments, the wireless charger further includes a sealing lip adjacent to or surrounding the cooling channel.

[0072] In some embodiments, the metal cover is made of aluminum and is configured to shield the vehicle from oscillating magnetic fields. BRIEF DESCRIPTION OF THE DRAWINGS

[0073] By way of example only, preferred embodiments of the present invention will now be described more fully with reference to the accompanying drawings, in which:

[0074] Figure 1 A garage is shown in a top view with a vehicle parked on a wireless charging provider, which is external to the vehicle and has a transmitter for transmitting an oscillating magnetic field;

[0075] Figure 2 Show Figure 1 A partial enlargement of the wireless charging supply and the wireless charger for charging the high voltage (HV) battery of the vehicle is shown;

[0076] Figure 3 Shown in close-up 3D view from Figure 2 Charger;

[0077] Figure 4 shows a cross section of a charger according to the prior art;

[0078] Figure 5 An exemplary embodiment (first embodiment) of the charger of the present invention is shown;

[0079] Figure 6 Another embodiment (second embodiment) is schematically shown, in which the metal cover is "donated" by the housing of the HV battery;

[0080] Figure 7 An exemplary embodiment (third embodiment) of a wireless charger is shown, which includes a coolant inlet and a coolant outlet that are machined or formed as non-conductive portions;

[0081] Fig. 8A and 8B Another embodiment (fourth embodiment) is schematically shown as a cross section and a perspective view, respectively; and

[0082] Fig.9A and 9B Another embodiment (fifth embodiment) is schematically shown as a cross section and a perspective view, respectively. DETAILED DESCRIPTION

[0083] Figure 1In a top view, a garage 1 is shown with a vehicle 2 parked on a wireless charging supply 3, which is outside the vehicle 2 and has a transmitter for sending an oscillating magnetic field. As the vehicle 2 is depicted as transparent, the supply 3 can be seen. Such a charging solution is very convenient and saves the driver from plugging and unplugging a charging cable.

[0084] Figure 2 Yes Figure 1 , and shows a wireless charging supply 3, and also shows a wireless charger 4 "floating" on the supply 3 for charging the high voltage (HV) battery of the vehicle 2. The charger 4 is built into the vehicle, which means that in this view, the rest of the vehicle is hidden.

[0085] Figure 3 The charger 4 is shown in a close-up 3D view.

[0086] Figure 4 A cross section of a charger 5 according to the prior art is shown. The charger 5 has a coil 6 configured to wirelessly receive the oscillating magnetic field from an external transmitter included in the wireless charging supply 3. The oscillating field induces an alternating current (AC) in the coil. A ferrite 7 is arranged adjacent to the coil 6. A cooling channel 8 is arranged adjacent to the ferrite 7 and is configured to provide a coolant flow. The flowing coolant cools a metal cover 9 in which the cooling channel is incorporated. An electrical component 10 for charging the HV battery based on AC is arranged adjacent to the metal cover for heat dissipation. The metal cover 9 separates the coil 6 and the ferrite 7 from the electrical component 10. The coil 6 and the ferrite 7 are embedded in a potting 11 protected by a coil cover 12. The potting 11 and the coil cover 12 are typically made of plastic.

[0087] Figure 4 A disadvantage of the described arrangement is that relatively high eddy current losses occur when the coil / ferrite 6 / 7 is arranged very close to the metal cover 9 and is not isolated from the metal cover 9. Furthermore, more specifically, Figure 4 The arrangement shown in leads to rather complex deformations due to thermal expansion, since the metal cover 9 is hooked into the magnetic assembly 11 / 12, which, as a plastic part, has a rather different thermal expansion coefficient than the metal cover 9. These relative movements may lead to material fatigue in the long term. In addition, the complex geometry of the metal cover 9 is difficult and expensive to realize.

[0088] Despite the existence Figure 5 The wireless charger according to the present invention has the above-mentioned difference. Figure 4 The components of the explanation. The one or more electrical components 10 (or Figure 514) may include at least one of a tuner, a rectifier, a DC / DC converter and an EMC filter. Furthermore, the wireless charger 13 may include a wireless data receiver (not shown) that allows the charging process to be controlled (in particular, the DC / DC converter to be controlled). Another optional component is a sensor (not shown) that can be used to determine the position of the charger 13 relative to the power supply (such as Figure 1 and 2 As shown in FIG. 3 , with the positioning of number 3 ), the vehicle has been parked on the provider.

[0089] Figure 5 An exemplary embodiment of the charger of the present invention is shown. The coil 15 and the ferrite 16 are embedded in a potting 17, which is embedded in a coil cover 18. The coil cover 18 has a recess 19 for receiving a lug 20 of the potting 17. The recess 19 is further configured to receive a lug 21 belonging to a non-conductive part 22. The non-conductive part 22 can be made of plastic, in particular by injection molding, for example. The advantages of this part 22 include: (a) it is in direct contact with the potting 20, which has a similar thermal expansion coefficient, so that there is almost no relative movement between the two parts due to thermal expansion; (b) it is lighter than the parts known in the prior art chargers; (c) it is easier and cheaper to manufacture; (d) it shields the metal cover 23 and the power electronics 14 from the oscillating magnetic field reaching the coil 15, thereby reducing eddy current losses during charging; (e) it allows the metal cover 23 to have a flat surface where it abuts the non-conductive part 22, so that during thermal expansion, the relative movement does not cause excessive tension.

[0090] The metal cover 23 can be glued to the non-conductive part 22, wherein the adhesive bond can compensate for the relative movement when the system is heated or cooled. The cooling channel 24 is formed by a recess in the non-conductive part 22 closed by the adjacent metal cover 23. The non-conductive part 22 (especially made of plastic) has a relatively low thermal conductivity. However, since most of the heat (or at least: the highest heat density) occurs on the side of the power electronic device 14, and the heat generation in the magnetic area (15-18) is well distributed and not so severe, the low thermal conductivity of the non-conductive part 22 is not a disadvantage. The direct contact between the coolant flowing through the cooling channel and the metal cover 23 ensures that heat is effectively removed from the electrical part 14. Optional geometries machined into the metal cover 23 (such as pins or fins immersed in the recess) can further improve heat dissipation.

[0091] The advantage of having two separate parts, one of which is highly thermally conductive and the other is not, further symmetrically forming cooling channels, is that the metal cover can also be used for further purposes. In other words, the part used as the metal cover can be "borrowed" from a different part of the vehicle (such as the body or the housing of the HV battery).

[0092] Figure 6 The latter example is schematically shown. In this embodiment, the battery housing 25 houses the HV battery 26 and the power electronics 27 necessary for charging the HV battery 26 based on the AC generated in the coil by wirelessly receiving the oscillating magnetic field of the transmitter from the external supply. These power electronics 27 correspond to Figure 5 The area where the magnetic device 28 is mounted on the battery housing 25 corresponds to the area where the magnetic device 28 is mounted on the battery housing 25. Figure 5 The metal cover 23 is shown in FIG. The magnetic device 28 corresponds to the coil 15 , the ferrite 16 , the potting 17 and the coil cover 18 .

[0093] Figure 6 One advantage of the configuration shown in is reduced weight, as at least one portion can be omitted. Another benefit is that the wireless charger (or at least portions thereof) can be retrofitted to vehicles that may not already have such features (assuming the electronics 27 are pre-installed). Furthermore, the routing of the coolant through the plastic portion 22 may have the benefit that it may melt in the event of a fire, and thereby release coolant to help extinguish the fire.

[0094] In another embodiment, if Figure 7 As shown in , the wireless charger includes a coolant inlet 29 and a coolant outlet 30, both of which are machined or formed into the non-conductive part 22. If injection molding technology is used for the production of the non-conductive part 22, the formation of the coolant inlet 29 and the coolant outlet 30 is very easy and cheap to achieve. A coolant pump (not shown) can be connected to the coolant inlet 29 and the coolant outlet 30 and installed next to the charger 13, for example.

[0095] Fig. 8A and 8B A further exemplary embodiment is schematically shown as a cross section and as a perspective view, respectively.

[0096] The power converter assembly 13 is configured to convert the electromagnetic power of the oscillating electromagnetic field into the electric power of the current for charging the electric storage device or exciting the electric load. The power converter assembly includes a magnetic component MA for receiving the oscillating electromagnetic field and converting it into an alternating current. The power converter assembly also includes an electronic component PE for receiving the alternating current AC and converting it into a current for charging the electric storage device or exciting the electric load. In addition, the power converter assembly includes heat sinks P1, P2 for dissipating the heat generated by the magnetic component MA and the electronic component PE during their respective power conversion operations.

[0097] The heat sink P1, P2 is arranged between the magnetic component MA and the electronic component PE and is in thermal contact with the magnetic component MA and the electronic component PE. The heat sink P1, P2 includes a first portion P1 in thermal contact with the magnetic component MA and a second portion P2 in thermal contact with the electronic component PE.

[0098] The first portion P1 comprises a first material and / or has a first structure suitable for dissipating heat flow from the magnetic component MA. The second portion P2 comprises a second material different from the first material and / or has a second structure different from the first structure suitable for dissipating heat flow from the electronic component PE.

[0099] Preferably, the first portion P1 is made of a polymer material that can be easily manufactured by moulding, for example by injection moulding.

[0100] Preferably, the second portion P2 is made of metal material.

[0101] Fig.9A and 9B Another embodiment (fifth embodiment) is schematically shown as a cross section and a perspective view, respectively.

[0102] Fig.9A and 9B The power converter assembly 13 shown in FIG. Fig. 8A and 8B The power converter assembly shown in is different in that the heat sink P1 , P2 , P3 comprises a third portion P3 arranged between the first portion P1 and the magnetic assembly MA.

[0103] Preferably, the first portion P1 is made of a polymer material that can be easily manufactured by moulding, for example by injection moulding.

[0104] Preferably, the second portion P2 is made of metal material.

[0105] Preferably, the third portion P3 is made of metal material.

[0106] An exemplary power converter assembly 13 or wireless charger 4, 13 for charging a high voltage (HV) battery 26 of a vehicle 2 includes:

[0107] a coil 15 configured to wirelessly receive an oscillating magnetic field from an external transmitter, thereby generating an alternating current (AC);

[0108] a ferrite 16 disposed adjacent to the coil;

[0109] a cooling channel 24 disposed adjacent to at least one of the ferrite and the coil, the cooling channel being configured to provide a coolant flow;

[0110] an electrical and / or electronic component 14 configured to charge the HV battery based on AC;

[0111] a metal cover 23 that separates the coil and the ferrite from the electrical components, at least one of which is disposed adjacent to the metal cover; and

[0112] The non-conductive portion 22 is configured to at least partially form a cooling channel and separate the coil and the ferrite from the metal cover.

[0113] The cooling passages 24 may be at least partially formed by recesses machined or formed in the non-conductive portion 22 .

[0114] The cooling channel 24 may be formed by the metal cover 23 closing the recess by abutting against the non-conductive portion 22 .

[0115] The cooling channel may be formed by a plate closing the recess by abutting the non-conductive portion, the plate separating the non-conductive portion from the metal cover.

[0116] Cooling channels may be incorporated into the non-conductive portion.

[0117] The metal cover 23 may be at least a portion of a housing 25 of the HV battery 26 .

[0118] The metal cover may include structures for enlarging the heat sink, which structures are immersed in the cooling channels.

[0119] A coolant inlet 29 and a coolant outlet 30 may be provided, both of which are machined or formed into the non-conductive portion 22 .

[0120] The metal cover 23 may be glued to the non-conductive portion 22 .

[0121] The metal cover 23 may be flat at least in a region adjacent to the non-conductive portion 22 .

[0122] The non-conductive portion 22 may be made of plastic.

[0123] The coil 15 and the ferrite 16 may be combined in a potting 17 .

[0124] The wireless charger (4, 13) according to claim 12, further comprising a coil cover (18) made of plastic, the potting (17) being embedded in the coil cover, and the coil cover being configured to engage with the non-conductive portion (22).

[0125] The converter assembly 13 or the wireless charger 4 , 13 may include a sealing lip adjoining or surrounding the cooling channel.

[0126] The metal cover may be made of aluminum and configured to shield the vehicle from oscillating magnetic fields.

[0127] Although the invention has been described above, in part with reference to some preferred embodiments, it must be understood that various modifications and combinations of the different features of the embodiments are possible. All these modifications are within the scope of the appended claims.

Claims

1. A power converter assembly (13) for converting electromagnetic power of an oscillating electromagnetic field into electrical power for charging an electrical storage device or exciting an electrical load, the power converter assembly comprising: a magnetic assembly (MA) for receiving the oscillating electromagnetic field and converting it into an alternating current (AC); an electronic component (PE) for receiving the alternating current (AC) and converting it into the current, wherein The power converter assembly (13) comprises a heat sink (P1, P2; P1, P2, P3) for dissipating heat generated by the magnetic assembly (MA) and the electronic assembly (PE) during their respective power conversion operations, characterized in that: a) the heat sink (P1, P2; P1, P2, P3) is arranged between the magnetic component (MA) and the electronic component (PE), and is in thermal contact with the magnetic component (MA) and the electronic component (PE); b) The heat dissipation device comprises: a first portion (P1) in thermal contact with the magnetic assembly (MA), and a second portion (P2) in thermal contact with said electronic component (PE); c) said first portion (P1) comprises a first material and / or has a first structure suitable for dissipating heat flow from said magnetic assembly (MA); d) The second portion (P2) comprises a second material different from the first material and / or has a second structure different from the first structure, the second structure being suitable for dissipating a heat flow from the electronic component (PE).

2. The power converter assembly according to claim 1, wherein: The first portion (P1) includes a first material having a first thermal conductivity, and the second portion (P2) includes a second material having a second thermal conductivity, the second thermal conductivity being greater than the first thermal conductivity.

3. The power converter assembly according to claim 1 or 2, wherein: The thermal conductivity of the second material is greater than 100 W (m·K).

4. The power converter assembly according to any one of claims 1 to 3, wherein: The first material and / or the second material is a metal, a metal alloy, a polymer, a polymer blend or a composite* material.

5. The power converter assembly according to any one of claims 1 to 4, wherein: The first material is a polymer or a polymer blend.

6. The power converter assembly according to any one of claims 1 to 5, wherein: The second material is a metal, a metal alloy or a composite* material.

7. The power converter assembly according to any one of claims 1 to 6, wherein: The first portion (P1) comprises a section defining ducts for a heat transfer fluid (coolant).

8. The power converter assembly according to claim 7, wherein: The first portion (P1) having the duct defining portion is produced by forming (shaping) a material in a mould.

9. The power converter assembly according to claim 8, wherein: The first portion (P1) having the duct defining portion is made by molding (casting, injecting) a moldable material in the mold.

10. The power converter assembly according to claim 8, wherein: The first portion (P1) having the duct defining portion is produced by sintering a sinterable material in the mould.

11. The power converter assembly according to claim 8, wherein: The first portion (P1) having the duct defining portion is produced by cross-linking a cross-linkable material in the mould.

12. The power converter assembly according to claim 7, wherein: The first portion (P1) having the duct-defining portion is manufactured in an additive layer-by-layer manner.

13. A power converter assembly according to any one of claims 7 to 12, wherein: The first part (p1) comprises a polymer.

14. The power converter assembly of claim 13, wherein: The first part (P1) comprises a polymer matrix in which particles are dispersed, the particles being selected from the group consisting of metal particles and graphite particles.

15. A power converter assembly according to any one of the preceding claims, wherein: The second portion (P2) comprises a solid metallic material.

16. A power converter assembly according to any one of the preceding claims, wherein: The second portion (P2) comprises a porous metal material.

17. A power converter assembly according to any one of the preceding claims, wherein: The second portion (P2) comprises a metal layer.

18. A power converter assembly according to any one of the preceding claims, wherein: The magnetic assembly (MA) comprises a coil (15).

19. The power converter assembly of claim 18, wherein: The magnetic assembly (MA) comprises a material (16) adjacent to the coil (15), the material (16) having a magnetic permeability greater than or equal to 1.

20. The power converter assembly of claim 19, wherein: The material (16) adjacent to the coil (15) is ferrite.

21. A power converter assembly according to any one of the preceding claims, wherein: The electronic component (PE) comprises a power electronics part.

22. A power converter assembly according to any one of the preceding claims, wherein: The heat sink (P1, P2; P1, P2, P3) comprises a third portion (P3) arranged between the first portion (P1) and the magnetic assembly (MA).

23. The power converter assembly of claim 22, wherein: The third portion (P3) comprises a solid metallic material.

24. A power converter assembly according to claim 22 or 23, wherein: The third portion (P3) comprises a porous metal material.

25. A power converter assembly according to any one of claims 22 to 24, wherein: The third portion (P3) comprises a metal layer.

26. A power converter assembly according to any one of claims 22 to 25, wherein: A three-part sandwich arrangement (P1, P2, P3) consisting of the first part (P1), the second part (P2) and the third part (P3) is arranged between the magnetic component (MA) and the electronic component (PE) and is in thermal contact with each of them.

27. A power converter assembly according to any one of claims 7 to 26, wherein: A conduit (24) for a heat transfer fluid defined by the material of the first portion (P1) includes a plurality of flow obstacles extending across the conduit (24).

28. The power converter assembly of claim 27, wherein: At least some of the flow obstacles are formed integrally with the first portion (P1).

29. A power converter assembly according to claim 27 or 28, wherein: At least some of the flow obstacles are formed integrally with the second portion (P2).

30. A power converter assembly according to any one of claims 27 to 29, wherein: At least some of the flow obstacles are integrally or monolithically formed with the third portion (P3).

31. A power converter assembly according to any one of claims 7 to 30, wherein: The first portion (P1) comprises a functional portion (29, 30) formed integrally with the conduit defining material of said first portion (P1).

32. The power converter assembly of claim 31, wherein: The functional portion includes at least one of a heat transfer fluid (coolant) inlet (29), a heat transfer fluid (coolant) outlet (30), a vent (breathing element), and an interface structure.

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