Main coil assembly for ground module GPM or vehicle module CPM of inductive charging system of vehicle

Abstract

The invention relates to a main coil assembly for a ground module (GPM) or a vehicle module (CPM) of an inductive charging system of a vehicle, comprising a main coil (101). The invention is characterized in that the main coil (101) is designed to have at least one current conductor (102), which is arranged in a space between a first boundary surface (103) and a second boundary surface (104) of the main coil assembly, through which a fluid can flow, such that the fluid can flow around the current conductor (102), and guiding / holding the at least one current conductor (102) in a predetermined coil geometry and in a predetermined coil position in the space by means of separate and spaced-apart guiding and / or holding elements (105).

Description

[0001] The present invention relates to a main coil assembly for a ground module (GPM) or a vehicle module (CPM) of an inductive charging system for a vehicle. The main coil assembly includes at least one main coil. Typically, in an inductive charging system, energy is inductively transferred from the main coil of the ground module (GPM) to the main coil of the vehicle module (CPM) in the vehicle to charge a storage unit / battery and / or operate 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 vice versa.

[0002] The GPM is typically mounted on the ground outside the vehicle, while the CPM is located on the vehicle, typically underneath. Electromagnetic coupling between the GPM's primary coil and the CPM's primary coil enables energy to be transferred from the GPM to the CPM, thereby charging the vehicle's battery.

[0003] The GPM and CPM typically each include corresponding power electronics and primary coil assemblies. The GPM's primary coil and the CPM's primary coil are optimally positioned relative to each other to achieve optimal electromagnetic coupling between the two primary coils, allowing energy to be inductively transferred from the GPM's primary coil to the CPM's primary coil, and vice versa (bidirectional).

[0004] The object of the present invention is to provide a main coil assembly for a ground module GPM or a vehicle module CPM of an inductive charging system for a vehicle, which assembly can achieve a simple manufacturing process, use less materials, have reliable product quality and better cooling effect.

[0005] The invention is derived from the features of the independent claims. Advantageous developments and embodiments are the subject matter of the dependent claims. Further features, applications, and advantages of the invention will become apparent from the following description and from the discussion of the exemplary embodiments of the invention shown in the accompanying drawings.

[0006] This object is achieved by a main coil assembly for a ground module GPM or a vehicle module CPM of an inductive charging system for a vehicle, wherein the main coil assembly comprises a main coil. The main coil assembly is further characterized in that the main coil is designed to have at least one current conductor, which is arranged in a fluid-flowable space between a first boundary surface and a second boundary surface of the main coil assembly so that the fluid can flow around the current conductor itself, and the at least one current conductor is guided / retained in a predetermined coil geometry and a predetermined coil position in the space by separate and spaced-apart guiding and / or retaining elements.

[0007] The main coil is preferably designed as a flat coil. Advantageously, at least one current conductor of the flat coil is arranged in one plane. If the main coil has more than one current conductor, the multiple current conductors can advantageously be arranged in multiple planes aligned parallel to one another.

[0008] The first and second boundary surfaces are advantageously aligned substantially parallel to one another. Advantageously, the first and / or second boundary surfaces are configured to be fluid-tight. If both boundary surfaces are designed to be fluid-tight, both fluid inflow and fluid outflow occur laterally through the side surfaces, for example, perpendicularly to the first and second boundary surfaces. Advantageously, the side surfaces are designed such that at least two areas of the side surfaces allow fluid inflow or outflow, while the remaining side surface areas are designed to be fluid-tight. The fluid is advantageously ambient air.

[0009] Advantageously, an airflow generator (e.g., a fan, propeller, etc.) is present in the main coil assembly or an adjacent assembly, imparting a flow velocity to the fluid, causing it to flow into or out of the space. Advantageously, the flow of the fluid within the space is directed by targeted localized flow influences. Such flow influences include, for example, targeted changes in localized flow resistance within the flow space, targeted changes in localized heat transfer between the fluid surface and boundary surfaces of the fluid flow, and / or targeted delays or inductions of localized flow separation within the flow space (e.g., targeted inductions of transitions from laminar to turbulent flow).

[0010] Advantageously, flow-guiding elements are arranged in the flow-through space (eg, profiled elements) for specific influencing of the local flow direction. These flow-guiding elements bring about a targeted change in the flow direction in the wake of the respective element.

[0011] To improve cooling or heat dissipation from the main coil assembly, it is crucial that the current conductors are arranged in this space so that a fluid can flow around them. Advantageously, the fluid can flow completely around the surface of at least one current conductor of the main coil, i.e., possibly up to those points on the current conductor's surface that are covered by the guiding and / or retaining elements. Advantageously, the at least one current conductor is arranged in this space in a substantially "free-floating" manner by the guiding and / or retaining elements.

[0012] In an advantageous embodiment, at least one current conductor is arranged in contact with the first boundary surface or the second boundary surface. In this case, the fluid advantageously flows around the surface of the at least one current conductor upwards to the contact surface of the current conductor on the respective boundary surface and, if appropriate, to those surface locations of the current conductor that are covered by the guiding and / or retaining element.

[0013] The guiding and / or holding elements arranged separately and at a distance from one another serve, on the one hand, to guide / hold at least one current conductor of the main coil in a predetermined coil geometry and, on the other hand, to guide / hold it in a predetermined coil position or current conductor position in the space.

[0014] Advantageously, the guiding and / or retaining element is designed at least partially as a spacer between the first boundary surface and the second boundary surface and connects them. Advantageously, the guiding and / or retaining element has a cylindrical shape. Advantageously, the guiding and / or retaining element is designed at least partially for locally securing the current conductor to the guiding and / or retaining element. For example, the guiding and / or retaining element each has a clip or other fastening mechanism for locally securing the current conductor.

[0015] The guide and / or retaining elements are particularly advantageously designed to specifically influence the flow direction in the flow tail of the respective guide and / or retaining element, so that the flow direction upstream of the guide and / or retaining element specifically differs from the flow direction downstream in the tail of the guide and / or retaining element. The flow in the space is preferably influenced in such a way that the fluid has the highest flow velocity and thus the highest mass throughput in those areas of the space where the heat generation during operation of the main coil is highest.

[0016] An advantageous further development is characterized in that the at least one current conductor consists of at least one strand having a plurality of individual wires each twisted together, wherein the individual wires each have a non-conductive coating, and the strand has a sheath made of plastic and / or wire.

[0017] Advantageously, the current conductor consists of a plurality of wires wound together, the wound wires having a plastic and / or silk sheath. Advantageously, the sheath is a multilayer structure made of layers of different materials. Advantageously, the sheath consists of one or more of the following materials: ETFE: refers to ethylene-tetrafluoroethylene plastic; PTFE: refers to polytetrafluoroethylene (polytetrafluoroethylene) plastic; FEP: refers to fluoroethylene-propylene plastic; Polymer alloy: refers to a polymer alloy made by mixing (compounding) two or more polymers or copolymers; Polyamide: refers to a linear polymer with regularly repeating amide bonds in the main chain; FR4: FR-4 or FR4 refers to a type of fire-resistant and flame-retardant composite material composed of epoxy resin and glass fiber fabric.

[0018] The material of the current conductor forming the sheath of the strand is advantageously chosen such that: Flammability is ensured according to the UL94V-0 specification, "Tests for Flammability of Plastic Materials for Parts in Devices and Appliances." This specification describes the method for evaluating and classifying the flammability of plastics. It has been incorporated into the IEC / DIN EN 60695-11 and -20 standards and the Canadian CAN / CSAC22.2 No. 017 standard with identical content.

[0019] - Classification of test specimen thicknesses into HB (horizontal burning test) and V-0, V-1, V-2, 5VA and 5VB (vertical burning test) grades. These standards - in order of required grades - are specifically used for: HB: Slow combustion of horizontally clamped samples (self-extinguishing or thickness < 3 mm; rate < 75 mm / min (HB75); thickness 3…13 mm; rate < 40 mm / min (HB40)).

[0020] V-2: The vertically clamped sample extinguishes within 30 seconds. The burning plastic melt is allowed to drip.

[0021] V-1: Similar to V-2, but does not allow burning dripping of the plastic melt. Maximum afterglow 60 seconds.

[0022] V-0: Same as V-1, but flame goes out in 10 seconds. Maximum afterglow 30 seconds.

[0023] - the sheath of the current conductor held by the guiding and / or retaining element is not subject to wear due to thermal expansion of the current conductor; - The sheath has a material durability of at least 15 years; - the breakdown voltage of the sheath conductor is at least 3 kV; - The sheath is resistant to substances present in the road environment, in particular gasoline, diesel, synthetic oils, natural oils, salt water, cleaning fluids, brake fluids, etc. - The water absorption of the sheath is as low as possible - in any case the breakdown voltage must not be less than 3kV; - The sheathed conductor is thermally stable in the range of -40°C to 100°C; - The sheathed conductor allows a minimum bending radius of 70 mm; - The sheathed conductor resists mechanical impact from particles entrained in the fluid flow; - Sheathed conductors are resistant to UV radiation; -Jacketed conductors resist ozone and other harmful gases present in the near-ground atmosphere.

[0024] Advantageously, the sheath of the current conductor has the highest possible thermal conductivity.

[0025] A particularly preferred embodiment is characterized in that the current conductor consists of a plurality of twisted strands, each strand having a plurality of twisted individual wires, wherein the individual wires each have a non-conductive coating, and in that the twisted strands have a first sheath made of a first polymer alloy and a second sheath made of a second polymer alloy coated thereon.

[0026] Further advantages, features and details will emerge from the following description, in which - possibly with reference to the accompanying drawings - at least one exemplary embodiment is described in detail. Identical, similar and / or functionally identical components are provided with the same reference numerals.

[0027] In the attached figure: Figure 1 A schematic diagram of a main coil assembly of a ground module GPM or a vehicle module CPM of an inductive charging system for a vehicle is shown in an oblique perspective, wherein the main coil assembly has a main coil 101 arranged on a first boundary surface 103 .

[0028] Figure 2 A detailed schematic diagram of the main coil 101 arranged on the first boundary surface 103 is shown in an oblique perspective.

[0029] Figure 3 A schematic side view of a main coil 101 arranged between a first boundary surface 103 and a second boundary surface 104 is shown.

[0030] Figure 1 A schematic diagram of a main coil assembly of a ground module GPM or a vehicle module CPM of an inductive charging system for a vehicle according to the present invention is shown, wherein the main coil assembly has a main coil 101 arranged on a first boundary surface 103. Main coil 101 is designed as a flat coil with a rounded rectangular spiral coil geometry and a current conductor 102. Current conductor 102 has electrical connections (marked by circles) at its two ends.

[0031] The current conductor 102 is arranged in a space between a first boundary surface 103 and a second boundary surface 104 (not shown) of the main coil assembly, through which a fluid (in this case ambient air) can flow, such that ambient air can flow around the current conductor 102 .

[0032] Furthermore, the at least one current conductor 102 is guided and held in a predetermined coil geometry and in a predetermined coil position in the space by separate and spaced-apart guiding and / or holding elements 105 .

[0033] Figure 2 A detailed schematic diagram of a main coil 101 arranged on a first boundary surface 103 is shown in an oblique perspective. The guide and / or retaining elements 105 shown have a cylindrical form, wherein these cylindrical guide and / or retaining elements 105 guide and retain the current conductor 102 in a predetermined coil geometry. The guide and / or retaining elements 105 can also be shown in the form of cable clamps that hold the current conductor 102 in a predetermined position. Finally, the guide and / or retaining elements It has a shape which, in addition to the function of guiding and holding the current conductor 102 , is also designed to influence the flow direction of the fluid, ie the flowing ambient air, in a targeted manner.

[0034] Figure 3 A schematic side view of a main coil 101 arranged between a first boundary surface 103 and a second boundary surface 104 is shown. In the space between the first boundary surface 103 and the second boundary surface 104 through which ambient air can flow, a current conductor 102 of the main coil 101 is arranged in contact with the first boundary surface.

[0035] Although the present invention has been further shown and described in detail by way of preferred exemplary embodiments, the present invention is not limited to the disclosed examples and other variations may be derived therefrom by those skilled in the art without departing from the scope of the invention. It is therefore apparent that various possible variations exist. It is also apparent that the exemplary embodiments are merely examples in nature and that these examples should not be interpreted in any way as limiting the scope, applicability or configuration of the invention. On the contrary, the foregoing description and the description of the accompanying drawings enable those skilled in the art to implement the exemplary embodiments and, knowing the disclosed inventive concepts, may make various changes, such as with respect to the function or arrangement of the various elements referenced in the exemplary embodiments, without departing from the scope defined by the claims and their legal equivalents, such as the broader interpretation in the specification.

[0036] Reference Signs List 101 main coil 102 current conductor 103 first boundary surface 104 second boundary surface 105 Guiding and / or retaining element.

Claims

1. A main coil assembly for a ground module (GPM) or a vehicle module (CPM) of an inductive charging system for a vehicle, wherein: The main coil assembly comprises a main coil (101), It is characterized in that - the main coil (101) is provided with at least one current conductor (102), - the at least one current conductor (102) is arranged in a fluid-flowable space between a first boundary surface (103) and a second boundary surface (104) of the main coil assembly, such that the fluid can flow around the current conductor (102), and - guiding / holding the at least one current conductor (102) in a predetermined coil geometry and in a predetermined coil position in the space by means of separate and spaced-apart guiding and / or holding elements (105).

2. The main coil assembly according to claim 1, It is characterized by: The guide and / or retaining element (105) is designed at least partially as a spacer between the first boundary surface (103) and the second boundary surface (104) and connects the first boundary surface (103) and the second boundary surface (104).

3. The main coil assembly according to claim 1 or 2, It is characterized in that The guide and / or retaining element (105) is designed as a guide element for guiding the fluid.

4. The main coil assembly according to any one of claims 1 to 3, It is characterized in that The guide and / or retaining element (105) is designed at least partially for local fixing of the current conductor (102).

5. The main coil assembly according to any one of claims 1 to 4, It is characterized by: The at least one current conductor (102) consists of at least one strand having a plurality of individual wires which are each twisted together, wherein the individual wires each have a non-conductive coating and the strand has a sheath made of plastic and / or wire.

6. The main coil assembly according to claim 5, It is characterized by: The current conductor (102) consists of a plurality of strands twisted together, wherein the twisted strands have a sheath made of plastic and / or wire.

7. The main coil assembly according to claim 5 or 6, It is characterized in that The sheath is a multi-layer structure made of layers of different materials.

8. The main coil assembly according to any one of claims 5 to 7, It is characterized by: The sheath is composed of one or more of the following materials: - Ethylene tetrafluoroethylene (ETFE), - Polytetrafluoroethylene plastic (PTFE), - Fluorinated ethylene-propylene (FEP), - polymer alloys, -polyamide, -FR4.

9. The main coil assembly according to any one of claims 1 to 4, It is characterized by: The current conductor (102) is composed of a plurality of strands wound together, each of the strands having a plurality of individual wires wound together, wherein the individual wires each have a non-conductive coating, and the wound strands have a first sheath made of a first polymer alloy and a second sheath made of a second polymer alloy coated thereon.

10. The main coil assembly according to any one of claims 1 to 9, It is characterized by: The fluid is ambient air.

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