On-board module (CPM) for inductive charging system of vehicle

Abstract

The present invention relates to an onboard board module (CPM) for an inductive charging system of a vehicle, comprising: a primary coil assembly for converting an electromagnetic field into an alternating current; the electronic component is used for converting alternating current into direct current; a heat dissipation device having an outer surface made of a non-conductive plastic material and in thermal contact with the main coil assembly and / or the electronic assembly, in which the outer surface dissipates heat generated during a power conversion operation of the main coil assembly and the electronic assembly into the environment, the outer surface (101) being formed by a plurality of structural elements (103), and a plurality of structural elements (103) which are individually arranged on an unstructured, smooth reference surface (102) of the outer surface (101), and each structural element (103) is raised above the reference structure (102).

Description

Technical Field

[0001] The present invention relates to an on-vehicle board module (CPM) for an inductive charging system for a vehicle. Furthermore, the present invention relates to an inductive charging system for a vehicle for charging an electrical storage device of the vehicle and comprising at least one ground board module (GPM) and an on-vehicle board module (CPM) of the same type. Furthermore, the present invention relates to a vehicle having such an on-vehicle board module (CPM). Background Art

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

[0003] The GPM and the CPM generally both include electronic components and a primary coil assembly having a primary coil. To achieve an optimal electromagnetic coupling of the two primary coils for energy transfer, 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 mainly generated in two regions in the GPM and the CPM: (a) in the respective electronic components, where a large amount of heat is generated relatively concentrated at certain positions 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. Summary of the Invention

[0005] The object of the present invention is to provide an improved and low-cost on-vehicle board module (CPM) with cooling.

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

[0007] A first aspect of the present invention relates to an on-vehicle board module (CPM) for an inductive charging system for a vehicle, comprising: a primary coil assembly for converting a received electromagnetic field into alternating current; an electronic assembly for converting the alternating current into direct current; and a heat dissipation device having an outer surface made of a non-conductive plastic material, wherein the outer surface is in thermal contact with the primary coil assembly and / or the electronic assembly, wherein the outer surface dissipates heat generated by the primary coil assembly and / or the electronic assembly during power conversion operation to the environment, and the outer surface is formed by a plurality of structural elements, the plurality of structural elements being individually arranged on an unstructured, smooth reference surface of the outer surface, each of the structural elements protruding above the reference surface. The individual structural elements enlarge the surface and thus enhance heat transfer to the environment (especially ambient air).

[0008] Advantageously, the structural elements are arranged in at least a part of the reference surface in a completely uniform distribution or a completely non-uniform distribution or a random distribution. The reference surface can in particular be a virtual reference surface assigned to the outer surface, from which all the structural elements extend in a protruding form.

[0009] Advantageously, the on-vehicle board module (CPM) has a housing having a housing outer surface, wherein when the on-vehicle board module (CPM) is installed in a vehicle, a structured outer surface is present in the region of the housing outer surface that forms the underside of the vehicle. Heat generated during power conversion in the CPM is dissipated to the ambient air via the housing outer surface located on the underside of the vehicle. Preferably, the structural elements are designed such that they remain substantially undamaged in the event of an external mechanical impact (e.g., due to stone impact or due to the vehicle resting on the housing outer surface) on the outer surface of the housing outer surface.

[0010] Advantageously, the structural elements are arranged directly adjacent to each other on the reference surface as a defect-free array or are arranged spaced apart from each other on the reference surface as a defect-free array, preferably in a row-column manner.

[0011] Advantageously, all the structural elements are identical in terms of their three-dimensional (3-D) shape. In an alternative embodiment, at least some of the structural elements are designed to be different in terms of their three-dimensional shape.

[0012] Particularly advantageously, each outer surface of the structural element forms an inclination angle (NW) with the reference surface extending from the reference surface, and the range of this inclination angle (NW) is 0° < NW < 90° or 30° < NW < 60°. In particular, this inclination angle (NW) is 45°. In addition, advantageously, the adjacent inclined outer surfaces of different structural elements form an angle (WE) with each other, and the range of this angle (WE) is 90° ≤ WE < 180° or 90° < WE < 150° or 90° < WE < 120°. Or in particular, this angle (WE) is equal to 90°. This ensures that the thermal radiation emitted from the outer surface of the structural element is basically radiated into the environment without heating the adjacent outer surface of the structural element.

[0013] Particularly advantageously, at least one, several or all of the structural elements are designed as a pyramid, a cone or a hipped roof, wherein the corresponding base surface of the pyramid, the cone or the hipped roof is arranged on the reference surface. The tip of the corresponding pyramid or cone can be rounded.

[0014] In another advantageous embodiment, at least one, several or all of the structural elements are designed as a truncated pyramid, a truncated cone or a mansard flat roof, wherein the corresponding base surface of the truncated pyramid, the truncated cone or the mansard flat roof is arranged on the reference surface.

[0015] Advantageously, the pyramid or the truncated pyramid can have a triangular, rectangular, hexagonal or octagonal base.

[0016] Another advantageous improvement of the vehicle-mounted board module (CPM) is characterized in that the outer surface mainly comprises or only comprises structural elements, and each structural element is designed as a pyramid, a cone or a hipped roof. In the case of an external mechanical impact on the outer surface of the housing, a "soft" impact protection is formed, although the wear resistance is relatively low.

[0017] Another advantageous improvement of the vehicle-mounted board module (CPM) is characterized in that the outer surface mainly comprises or only comprises structural elements, and each structural element is designed as a truncated pyramid, a truncated cone or a mansard flat roof. In the case of an external mechanical impact on the outer surface of the housing, a "hard" impact protection is formed, and the wear resistance is relatively high.

[0018] Another advantageous improvement feature of the on-vehicle board module (CPM) is that the outer surface alternately has structural elements designed as pyramids, cones, or hip roofs and structural elements designed as truncated pyramids, truncated cones, or platform-folded roofs in one area. In the case of external mechanical impacts on the outer surface of the housing, "medium" impact protection is formed, and its wear resistance is medium.

[0019] Advantageously, the outer surface of the heat dissipation device is made of a non-conductive material. Advantageously, the outer surface of the heat dissipation device is produced by molding, casting, or injecting materials into a mold. Advantageously, the outer surface of the heat dissipation device is produced by sintering a sinterable material in a mold. Advantageously, the outer surface of the heat dissipation device is produced by crosslinking a crosslinkable material in a mold. Advantageously, the outer surface of the heat dissipation agent is additively produced in a layer-by-layer processing technique. Advantageously, the outer surface of the heat dissipation device includes a polymer material. Advantageously, the outer surface of the heat dissipation device is made of a ceramic material. Advantageously, the outer surface of the heat dissipation device is made of a composite material. Advantageously, the outer surface of the heat dissipation device includes a fiber-reinforced polymer matrix, where the fibers are made of a non-conductive material. Advantageously, the outer surface of the heat dissipation device includes a polymer matrix with dispersed particles therein, where the fibers are made of a non-conductive material. Advantageously, the non-conductive material is selected from at least one of the following materials: boron nitride, silicon carbide.

[0020] The second aspect of the present invention relates to an inductive charging system for a vehicle, which is used to charge the energy storage device of the vehicle and includes at least one ground board module (GPM) and an on-vehicle board module (CPM), where energy is transferred between the ground board module (GPM) and the on-vehicle board module (CPM), and where the on-vehicle board module (CPM) is designed as described above.

[0021] The third aspect of the present invention relates to a vehicle having the on-vehicle board module (CPM) as described above. Description of the Drawings

[0022] Further advantages, features, and details will be obvious from the following description, where at least one exemplary embodiment is described in detail, optionally with reference to the drawings. Identical, similar, and / or functionally identical parts have the same reference numerals.

[0023] In the drawings: Figure 1 A schematic diagram showing a part of the outer surface of the heat dissipation device of the on-vehicle board module (CPM) according to the present invention is shown.

[0024] Figure 2 A schematic diagram showing the on-vehicle board module (CPM) having a housing, which is simultaneously part of the heat dissipation device and has an outer surface of the housing constructed according to the present invention, is shown.

[0025] Figure 3 A schematic diagram showing the internal structure of a vehicle-mounted board module (CPM) having a main coil assembly 105 and an electronic component 106 is shown. Detailed implementation

[0026] Figure 1 A schematic diagram showing a part of the outer surface of a heat dissipation device of a vehicle-mounted board module (CPM) according to the present invention is shown. The outer surface and the structural element 103 are made of a non-conductive plastic material. Advantageously, the plastic material itself is a good heat conductor. The plastic material is in thermally conductive contact with the main coil assembly and / or the electronic component, and its outer surface 101 dissipates the heat generated during the power conversion operation of the main coil assembly 105 and the electronic component 106 into the ambient air.

[0027] On a flat reference surface 101 (spanned here by the two vectors shown), a plurality of individually arranged structural elements 103 are arranged in the form of adjacent pyramids having a quadrilateral base region, and each structural element protrudes above the reference surface 102.

[0028] Each structural element outer surface 104 of the structural element 103 extending from the reference surface 102 encloses an inclination angle (NW) of approximately 45° with this reference surface 102 here. Correspondingly, the inclined structural element outer surfaces 104 of different structural elements 103 arranged directly adjacent (opposite to each other) are inclined at an angle of approximately 90° (WE) with respect to each other. The thermal radiation emitted from the structural element outer surface 104 basically does not heat the outer surface 101.

[0029] Figure 2 A schematic diagram of a vehicle-mounted board module (CPM) having a CPM housing is shown in an oblique view. When installed on a vehicle, Figure 2 the structured surface of the CPM housing shown in is arranged downward on the vehicle floor. The structured outer surface 101 of the CPM housing is also part of the heat dissipation device. The structured housing outer surface 101 has a plurality of pyramidal structural elements 103, and these structural elements are arranged in rows and columns directly adjacent to each other in a matrix manner.

[0030] Figure 3 A schematic diagram showing the internal structure of a vehicle-mounted board module (CPM) having a main coil assembly 105 and an electronic component 106 is shown. The main coil assembly particularly has a main coil, and in this case the main coil is designed as a flat coil.

[0031] Although the present invention has been shown and described in further detail by preferred exemplary embodiments, the present invention is not limited to the disclosed examples, and those skilled in the art can derive other variations therefrom without departing from the scope of the present invention. Therefore, it is obvious that there are various possible changes. It is also clear that the exemplary embodiments are actually only examples, and these examples should not be construed in any way as limiting the scope, applicability or configuration of the present invention. On the contrary, the foregoing description and the description of the drawings enable those skilled in the art to implement the exemplary embodiments, and these people can make various changes knowing the disclosed inventive concept, such as regarding the functions or arrangements of the various elements cited in the exemplary embodiments, without departing from the scope defined by the claims and their legal equivalents, such as the broader interpretations in the specification.

[0032] List of Reference Numerals 101 Outer surface of the heat dissipation device 102 Reference surface 103 Structural element 104 Outer surface of the structural element 105 Main coil assembly 106 Electronic component.

Claims

1. On-vehicle board module (CPM) for an inductive charging system for a vehicle, comprising: - A main coil assembly (105) for converting an electromagnetic field into alternating current; - An electronic assembly (106) for converting the alternating current into direct current, - A heat dissipation device having an outer surface (101) made of a non-conductive plastic material and in thermal contact with the main coil assembly and / or the electronic assembly, wherein the outer surface (101) dissipates heat generated during the power conversion operation of the main coil assembly and the electronic assembly to the environment, the outer surface (101) being formed by a plurality of structural elements (103), the structural elements (103) being individually arranged on an unstructured, smooth reference surface (102) of the outer surface (101), and each of the structural elements (103) protruding above the reference surface (102).

2. The vehicle-mounted board module (CPM) according to claim 1, wherein, The structural elements (103) are arranged in at least part of the reference surface (102) only in a uniform or non-uniform distribution.

3. The in-vehicle board module (CPM) according to claim 1 or 2, wherein, The on-vehicle board module (CPM) has a housing with a housing outer surface, wherein when the on-vehicle board module (CPM) is installed in the vehicle, the structured outer surface (101) is located in the area of the housing outer surface that forms the lower side of the vehicle.

4. The in-vehicle board module (CPM) according to any one of claims 1 to 3, wherein, Each of the structural elements (103) is arranged directly adjacent to each other on the reference surface (102) as a defect-free array.

5. The on-vehicle board module (CPM) according to any one of claims 1 to 3, wherein, Each of the structural elements (103) is arranged at intervals from each other on the reference surface (102) as a defect-free array.

6. The on-vehicle board module (CPM) according to any one of claims 1 to 3, wherein, The structural elements (103) are arranged on the reference surface (102) in a row-and-column manner.

7. The in-vehicle board module (CPM) according to any one of claims 1 to 6, wherein, Each structural element outer surface (104) of the structural elements (103) extending from the reference surface (102) encloses an inclination angle (NW) with the reference surface (102), the inclination angle (NW) ranging from 0° < NW < 90°, 30° < NW < 60°, or the inclination angle (NW) being 45°.

8. The on-vehicle board module (CPM) according to any one of claims 1 to 7, wherein, The closely arranged, inclined structural element outer surfaces (104) of different structural elements (103) each enclose an angle (WE), the angle (WE) ranging from 90° ≤ WE < 180° or 90° < WE < 150° or 90° < WE < 120°, or particularly the angle (WE) being equal to 90°.

9. The in-vehicle board module (CPM) according to any one of claims 1 to 8, wherein, At least one, several or all of the structural elements (103) are each designed as a pyramid, a cone or a hip roof, wherein the corresponding base surface of the pyramid or the cone or the hip roof is arranged on the reference surface (102).

10. The vehicle-mounted board module (CPM) according to any one of claims 1 to 9, wherein, At least one, several or all of the structural elements (103) are each designed as a truncated pyramid or a truncated cone or a platformed broken-line roof, wherein the corresponding base surface of the truncated pyramid or the truncated cone or the platformed broken-line roof is arranged on the reference surface (102).

11. An inductive charging system for a vehicle, which is used to charge a power storage device of the vehicle, and includes at least one ground plate module (GPM) and one vehicle-mounted plate module (CPM), wherein, Energy is transferred between the ground panel module (GPM) and the vehicle-mounted panel module (CPM), and wherein the vehicle-mounted panel module (CPM) is designed as the vehicle-mounted panel module (CPM) according to any one of claims 1 to 10.

12. A vehicle, the vehicle comprising a vehicle-mounted panel module (CPM) according to any one of claims 1 to 10.

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