Vehicle module CPM for an inductive charging system of a vehicle

Abstract

The present invention relates to a vehicle module (CPM) for converting electromagnetic energy of an electromagnetic field generated by sensing a ground module (GPM) of a vehicle charging system into electrical energy of an electrical current, and for charging an electrical storage device in a vehicle and / or for operating an electrical load in the vehicle, the vehicle module (CPM) comprising: a main coil assembly (101), the main coil is used for converting the electromagnetic field into alternating current (AC); and an electronic assembly (102) comprising power electronics (105) for converting an alternating current (AC) to a direct current (DC). The vehicle module (CPM) is characterized in that one or more heat pipes (103) are provided for transferring / distributing heat generated locally in the main coil assembly (101) and / or the electronic assembly (102) during an energy conversion operation, and the heat pipes (103) transfer the heat generated locally, in particular from the main coil assembly (101), to the electronic assembly (102), and vice versa. The electronic assembly (102) has a channel (104) through which a refrigerant fluid can flow and which can be connected to an external heat exchanger. The channel (104) is designed to transfer heat from the electronic component (102) to the refrigerant fluid.

Description

[0001] The present invention relates to a vehicle module CPM for an inductive charging system for a vehicle.

[0002] As is known, an inductive charging system for a vehicle generally includes a ground module (ground pad module; GPM) fixed to the ground and connected to the power grid and a vehicle module (car pad module; CPM) typically arranged under the vehicle. Generally, in such an inductive charging system, energy is inductively transferred through a primary coil of the ground module GPM to a primary coil of the vehicle module CPM arranged in the vehicle for charging an electrical storage unit / battery and / or for powering an electrical load. The ground module GPM and the vehicle module CPM can also be configured for bidirectional energy transfer, i.e., from GPM to CPM and from CPM to GPM.

[0003] Both the GPM and the CPM generally include electronic components and a primary coil assembly having a primary coil. To achieve optimal electromagnetic coupling for energy transfer between the two primary coils, the primary coil of the GPM and the primary coil of the CPM must be optimally positioned relative to each other.

[0004] During operation, i.e., during energy transfer from the primary coil to the primary coil, heat is generated in the GPM and in the CPM in generally two areas: (a) in the respective electronic components, where a large amount of heat is generated relatively concentratedly at certain locations with a high local heat density, and (b) in the respective primary coil assemblies (primary coil and ferrite), where less heat is generated relative to the electronic components and is relatively well distributed. The electronic components generally include power electronic devices.

[0005] The object of the present invention is to improve the heat dissipation of the vehicle module CPM from an inductive vehicle charging system.

[0006] The present invention results from the features of the independent claims. Advantageous refinements and embodiments are the subject of the dependent claims. Other features, possible applications, and advantages of the present invention will become apparent from the following description and from the discussion of the exemplary embodiments of the present invention depicted in the drawings.

[0007] A first aspect of the present invention relates to a vehicle module CPM for converting electromagnetic energy of an electromagnetic field generated by a ground module GPM of an inductive vehicle charging system into electrical energy of an electric current and for charging an electrical storage device in the vehicle and / or for operating an electrical load in the vehicle, wherein the vehicle module CPM includes: - a primary coil assembly having a primary coil for converting the electromagnetic field into an alternating current AC, and - an electronic component having power electronic devices for converting the alternating current AC into a direct current DC.

[0008] The proposed vehicle module CPM is characterized in that one or more heat pipes are provided for transferring / distributing the heat locally generated in the main coil assembly and / or the electronic assembly during the energy conversion operation, wherein the heat pipes transfer the locally generated heat especially from the main coil assembly to the electronic assembly and vice versa, and the electronic assembly has channels through which a refrigerant fluid can flow and which can be connected to an external heat exchanger, wherein the channels are configured and designed to transfer heat from the electronic assembly to the refrigerant fluid.

[0009] Accordingly, the heat locally generated in the vehicle module CPM during the energy conversion operation in the main coil assembly and in the electronic assembly is transferred between the aforementioned components by the heat pipes, such that the heat is distributed substantially equally between the two components. Generally, more heat is locally generated in the electronic assembly than in the main coil assembly. The channels through which the refrigerant fluid can flow and which are in thermally conductive contact with the electronic assembly and serve as heat sinks additionally dissipate heat from the area of the electronic assembly. In summary, on the one hand, the heat locally generated in the vehicle module is distributed substantially uniformly in the vehicle module or its housing by the heat pipes, and at the same time, heat is dissipated from the electronic assembly by the channels through which the refrigerant fluid flows. Together, these achieve on the one hand an improved cooling of the vehicle module CPM and on the other hand a higher electric power conversion in the vehicle module CPM.

[0010] The term "heat pipe" herein refers to a heat exchanger that allows a high heat flux density by utilizing the enthalpy of evaporation of a medium. In this way, a large amount of heat can be transferred over a small cross-sectional area. A basic distinction is made between two types of heat pipes: the so-called "heat pipe" and the so-called "two-phase thermosyphon". The basic operating principle is the same for both designs; the difference lies in the return conveyance of the gaseous working medium to the evaporator (i.e., to the point where heat is supplied). In both designs, the return conveyance is passive and thus without any aids such as a circulation pump.

[0011] At the operating temperature, the thermal resistance of a heat pipe is significantly lower than that of a metal. Therefore, the heat pipe behaves very close to an isothermal state change. Along the length of the heat pipe, there is an almost constant temperature. At the same transfer capacity and under the same operating conditions, a significantly lighter design is possible compared to a conventional heat exchanger. By carefully selecting the working medium of the heat pipe, operating temperatures from a few Kelvin to approximately 3000 Kelvin can be achieved.

[0012] The energy transfer capacity of a heat pipe depends to a large extent on the specific enthalpy of evaporation of the working medium (in kJ / mol or kJ / kg), rather than on the thermal conductivity of the container wall or the working medium. For efficiency reasons, the heat pipe is typically operated at a temperature slightly above the boiling temperature of the working medium at the hot end and at a temperature slightly below the boiling temperature of the working medium at the cold end.

[0013] Advantageously, compared to regions with low local heat generation, in regions of the main coil assembly and / or the electronic assembly that have high local heat generation during energy conversion operation, the heat pipes are arranged with a higher density (with a smaller distance between directly adjacent heat transfer elements).

[0014] Advantageously, the one or more heat pipes with a respective tube length L are arranged / are arranged relative to each other such that directly adjacent heat pipes are spaced apart by a distance D selected from the range: 3 < L / D < 10. This indicates the optimal value for the distance D of the heat pipes, such that a sufficient number of heat pipes can be used for a largely uniform temperature distribution within the CPM.

[0015] Advantageously, at least some of the plurality of heat pipes are arranged in two or more parallel planes within the vehicle module CPM. It is assumed that the heat pipes are designed such that their longitudinal extension extends in one plane. They can be designed as straight or curved. Advantageously, at least some of the plurality of heat pipes are arranged in at least two non-parallel planes within the vehicle module CPM. Advantageously, at least some of the plurality of heat pipes are arranged in two or more non-parallel planes within the vehicle module CPM.

[0016] Advantageously, at least some of the plurality of heat pipes are arranged in two or more mutually parallel planes within the vehicle module CPM.

[0017] Advantageously, at least some of the plurality of heat pipes are arranged in at least two non-parallel planes within the vehicle module CPM.

[0018] Advantageously, at least one heat pipe or, in particular, all heat pipes are arranged within the housing material of the housing of the vehicle module CPM and / or are arranged directly on the housing of the CPM and / or are in at least thermally conductive contact with the housing.

[0019] The main coil of the CPM advantageously includes at least one coil wire arranged in a coil wire arrangement in a predetermined geometry. In particular, the main coil of the CPM is designed as a flat coil.

[0020] Advantageously, the material adjacent to the main coil is a ferromagnetic or ferrimagnetic material.

[0021] Advantageously, at least one section of the at least one heat pipe is arranged substantially uniformly above and / or below at least one section of the coil wire. This allows the heat generated in the coil wire to be directly transferred to the heat pipe and distributed in the CPM through the heat pipe.

[0022] If the coil wire is arranged in at least one area of the CPM with an increased coil wire density, sections of the plurality of heat pipes are advantageously arranged in this area with a higher density compared to other areas where the coil wire is arranged with a low coil wire density.

[0023] Advantageously, the main coil consists of at least one coil wire and has at least one area with an increased coil wire density, in which area sections of the plurality of heat pipes are arranged with a higher density compared to other areas of the main coil.

[0024] Advantageously, one section of the one heat pipe or corresponding sections of the plurality of heat pipes are arranged above and / or below the coil wire arrangement in the intermediate area between individual coil wire windings.

[0025] Advantageously, the at least one coil wire of the coil wire arrangement is arranged / wound only in one coil wire plane, and the at least one heat pipe or the plurality of heat pipes are arranged parallel to the coil wire plane.

[0026] Advantageously, at least one of the heat pipes is arranged along the coil wire around which the coil wire is wound.

[0027] Advantageously, the at least one coil wire is wound around at least a part of the at least one heat pipe.

[0028] In an advantageous embodiment, the at least one coil wire is designed as a heat pipe.

[0029] Advantageously, the main coil of the main coil assembly of the CPM is embedded in a first thermally conductive material. Advantageously, the power electronic devices of the electronic assembly of the CPM are embedded in a second thermally conductive material, which is thermally connected to the first thermally conductive material.

[0030] Advantageously, the housing of the CPM is made of a material with a thermal conductivity λ > 100 W / ( ), in particular > 150 W / ( ).

[0031] Advantageously, the housing of the CPM has a structured outer surface that is in thermally conductive contact with one or more of the heat pipes.

[0032] Advantageously, the main coil assembly and the electronic assembly are arranged spatially separated from each other within the vehicle module CPM, with a wall arranged between the two assemblies, the wall being designed as a heat-conducting element. Advantageously, the heat-conducting element is composed of a material with a thermal conductivity λ > 10 W / ( ) or λ > 100 W / ( ) or λ > 150 W / ( ) or λ > 200 W / ( ) or λ > 300 W / ( ). Advantageously, at least one heat pipe is thermally connected to the heat-conducting element.

[0033] Advantageously, the main coil assembly includes a main coil, wherein the main coil is embedded in a first heat-conducting material.

[0034] Advantageously, the electronic assembly includes power electronics, wherein the power electronics are embedded in a second heat-conducting material, the second heat-conducting material being thermally connected to the first heat-conducting material.

[0035] Advantageously, the housing of the vehicle module CPM has a structured outer surface that is in thermal contact with one or more of the heat pipes. When the vehicle module is mounted on a vehicle, the outer surface advantageously faces downward and is advantageously freely exposed to the flow of ambient air.

[0036] A second aspect of the invention relates to an inductive charging system for a vehicle, the inductive charging system for charging an electrical storage device of the vehicle, having at least one ground module GPM and a vehicle module CPM, wherein energy is transferred at least from the ground module GPM to the vehicle module CPM, and wherein the vehicle module CPM is designed as described above.

[0037] A third aspect of the invention relates to a vehicle having a vehicle module CPM as described above.

[0038] In the drawings: Figure 1 A schematic representation of a vehicle module CPM according to the invention is shown.

[0039] Figure 1Shows a schematic representation of a vehicle module CPM according to the present invention, the vehicle module CPM being adapted to convert electromagnetic energy of an electromagnetic field generated by a ground module GPM of an inductive vehicle charging system into electrical energy of an electric current and to charge an electrical storage device in the vehicle and / or to operate an electrical load in the vehicle. The vehicle module CPM includes: a main coil assembly 101 having a main coil 106 for converting the electromagnetic field into alternating current AC; and an electronic assembly 102 having power electronics 105 for converting the alternating current AC into direct current DC.

[0040] The vehicle module CPM herein includes five heat pipes 103, which are arranged above the main coil for transferring / distributing heat locally generated in the main coil assembly 101 and / or the electronic assembly 102 during the energy conversion operation, wherein the heat pipes 103 transfer the locally generated heat from the main coil assembly 101 to the electronic assembly 102 and vice versa.

[0041] The electronic assembly 102 has a channel 104 through which a refrigerant fluid can flow and which can be connected to an external heat exchanger, wherein the channel 104 is configured and designed to transfer heat from the electronic assembly 102 to the refrigerant fluid substantially and thus discharge it.

[0042] The refrigerant fluid flows through the channel 104, as indicated by the associated arrow.

[0043] Although the present invention has been further illustrated and described in detail by preferred exemplary embodiments, the present invention is not limited by the disclosed examples, and other variations can be derived therefrom by those skilled in the art without departing from the scope of the present invention. Therefore, it is clear that there are various possible variations. It is also clear that the illustrated embodiments are in fact only examples, and the examples should not in any way be construed as limiting the scope, applicability or configuration of the present invention. Rather, the foregoing description and the description of the drawings enable those skilled in the art to implement the exemplary embodiments, and such persons can make various changes, such as with respect to the functions or arrangements of the various elements cited in one exemplary embodiment, without departing from the scope (such as the broader interpretation in the specification) defined by the claims and their legal equivalents, knowing the disclosed inventive concept.

[0044] List of reference numerals 101 Main coil assembly 102 Electronic assembly 103 Heat pipe 104 Channel 105 Power electronics 106 Main coil

Claims

1. A vehicle module CPM that is configured to convert electromagnetic energy of an electromagnetic field generated by inductively sensing a ground module GPM of a vehicle charging system into electrical energy of an electric current, and that is configured to charge an electrical storage device in the vehicle and / or to operate an electrical load in the vehicle, wherein, The vehicle module CPM includes: - A main coil assembly (101) having a main coil for converting the electromagnetic field into alternating current AC, and - An electronic assembly (102) having power electronics (105) for converting alternating current AC into direct current DC, Characterized in that - One or more heat pipes (103) are provided for transferring / distributing the heat locally generated in the main coil assembly (101) and / or the electronic assembly (102) during the energy conversion operation, wherein the heat pipe (103) transfers the locally generated heat especially from the main coil assembly (101) to the electronic assembly (102) and vice versa, and - The electronic assembly (102) has a channel (104) through which a refrigerant fluid can flow and can be connected to an external heat exchanger, wherein the channel (104) is configured and designed to transfer heat from the electronic assembly (102) to the refrigerant fluid.

2. The vehicle module CPM according to claim 1, It is characterized in that Compared with the region having low local heat generation, the heat pipes (103) are arranged with a higher density in the regions of the main coil assembly (101) and / or the electronic assembly (102) having high local heat generation during the energy conversion operation.

3. The vehicle module CPM according to any one of claims 1 to 2, It is characterized in that At least some of the plurality of heat pipes (103) are arranged in two or more parallel planes in the vehicle module CPM.

4. The vehicle module CPM according to any one of claims 1 to 3, It is characterized in that At least one heat pipe (103) is arranged in the housing material of the housing of the vehicle module CPM or directly on the housing.

5. The vehicle module CPM according to any one of claims 1 to 4, It is characterized in that The main coil assembly (101) and the electronic assembly (102) are arranged spatially separated from each other within the vehicle module CPM, and a wall designed as a heat conducting element is arranged between the two assemblies (101, 102).

6. The vehicle module CPM according to claim 5, It is characterized in that The heat-conducting element is composed of a material with a thermal conductivity λ > 10 W / ( ), or λ > 100 W / ( ), or λ > 150 W / ( ), or λ > 200 W / ( ), or λ > 300 W / ( ).

7. The vehicle module CPM according to any one of claims 1 to 6, It is characterized in that The main coil is embedded in a first heat conducting material, the power electronics (105) are embedded in a second heat conducting material, and the second heat conducting material is thermally connected to the first heat conducting material.

8. The vehicle module CPM according to any one of claims 1 to 7, It is characterized in that, The housing of the vehicle module CPM has a structured outer surface which is in thermal contact with one or more of the heat pipes (103).

9. An inductive charging system for a vehicle, the inductive charging system being configured to charge an electrical storage device of the vehicle, having at least one ground module GPM and one vehicle module CPM, wherein, Energy is transferred at least from the ground module GPM to the vehicle module CPM, and wherein the vehicle module CPM is designed according to any one of claims 1 to 8.

10. A vehicle having the vehicle module CPM according to any one of claims 1 to 8.

Images