Integrated wireless charging subframe for vehicle

Abstract

The present application discloses an integrated wireless charging subframe (1) for a vehicle, characterized by comprising: an upper housing (10); a lower case (12) connected to the upper case (10) from below; a heat sink (14) provided on the bottom surface of the lower case (12); a charging module housing (16) connected to the heat sink (14); the anti-vibration base plate (18) is arranged on the inner side of the charging module shell (16); a charging module (20) disposed in the charging module housing (16); and the protective cover (22) is arranged at the bottom of the charging module (20).

Description

Technical Field

[0001] The present application relates to the field of electric vehicles, and in particular to an integrated wireless charging subframe for electric vehicles. Background Art

[0002] Wireless charging technology for electric vehicles (EVs) is developing rapidly, offering a convenient and efficient alternative to traditional plug-in charging. Inductive power transfer (IPT) is the most commonly used technology for wireless charging of EVs. It uses a magnetic field to transfer energy between a charging pad on the ground (which contains a transmitting coil) and a receiving coil on the bottom of the electric vehicle. When the electric vehicle is parked on the charging pad, the magnetic field generates an electric current in the receiver, which charges the battery. Currently, wireless charging efficiency is comparable to plug-in charging. The receiving coil of a wirelessly charged EV is typically located at the bottom of the vehicle, near the center of the chassis. While the receiving coil needs to be close to the ground, it also needs to be high enough to avoid obstacles and maintain sufficient ground clearance.

[0003] The receiver coil, a key component of an electric vehicle's wireless charging system, isn't typically mounted directly on the subframe. The subframe already houses suspension components, steering gear, and possibly even the battery module. Wireless charging generates heat, and the receiver coil requires adequate ventilation to dissipate the heat. Mounting it within the confines of a subframe can hinder heat dissipation. Utility Model Content

[0004] In order to solve the problems in the prior art, the present application proposes an integrated wireless charging subframe.

[0005] The present application specifically discloses an integrated wireless charging subframe for a vehicle, comprising: an upper shell; a lower shell connected to the upper shell from below; a radiator arranged on the bottom surface of the lower shell; a charging module shell connected to the radiator; an anti-vibration pad arranged on the inner side of the charging module shell; a charging module arranged in the charging module shell; and a protective cover arranged at the bottom of the charging module.

[0006] According to an optional embodiment, the upper housing is connected to a frame of the vehicle and has an opening extending vertically therethrough; and the opening of the upper housing is sized to allow the charging module housing to pass through the upper housing.

[0007] According to an optional embodiment, the lower housing is provided with an opening at a position corresponding to the opening of the upper housing; and the size of the opening of the lower housing is set to allow the charging module housing to pass through the lower housing.

[0008] According to an optional embodiment, the radiator includes a plurality of heat dissipation bars arranged in a mesh; the radiator is provided with an opening at a position corresponding to the opening of the upper shell; and the size of the opening of the radiator is set to allow the charging module shell to be set in the opening of the radiator.

[0009] According to an optional embodiment, the lower shell is provided with a plurality of grooves arranged in a mesh shape on the bottom surface corresponding to the plurality of heat dissipation bars of the radiator; and the charging module shell extends in a vertical direction through the opening of the lower shell and the opening of the upper shell.

[0010] According to an optional embodiment, the charging module includes a plurality of heat dissipation fins arranged on its outer surface; and the plurality of heat dissipation fins are spaced apart from each other and contact the inner wall of the charging module housing at the ends to conduct the heat of the charging module to the charging module housing.

[0011] According to an optional embodiment, the charging module includes a controller, a temperature sensor, a power sensor and a receiving coil arranged at the bottom; the temperature sensor and the power sensor are respectively connected to the controller to send the measured temperature and power of the charging module to the controller; and the controller is configured to adjust the charging parameters according to the temperature and power of the charging module to maintain the charging module within a safe range.

[0012] According to an optional embodiment, the length of the receiving coil is in the range of 320 mm to 420 mm, and the width is in the range of 50 mm to 90 mm.

[0013] According to an optional embodiment, the integrated wireless charging sub-frame includes a connector; the connector passes through the protective cover and the charging module to connect the protective cover and the charging module to the lower housing.

[0014] According to an optional embodiment, the upper housing, the heat sink and the charging module housing are made of aluminum; the lower housing is made of plastic; and the anti-vibration pad is made of rubber.

[0015] In the integrated wireless charging subframe according to the present application, the receiving coil is integrated into the subframe, effectively improving the overall stiffness and strength of the vehicle's bottom structure. This is particularly beneficial for large vehicles or vehicles that bear heavier loads. Integrating the receiving coil into the subframe helps suppress vibrations and reduce noise transmitted from the road surface to the passenger compartment. Encapsulating the receiving coil within the subframe can provide additional protection for the receiving coil from impact with road debris or obstacles, and can further protect the receiving coil from moisture, dust, and other environmental factors. A more integrated design can reduce resistance at the bottom of the vehicle, thereby improving the vehicle's aerodynamic performance. Integrating the receiving coil within the subframe can also free up space in other areas of the vehicle's bottom, allowing for more efficient packaging of battery packs or other components.

[0016] The integrated wireless charging subframe according to the present application includes a dedicated heat sink, which can effectively improve the heat conduction of the subframe, thereby acting as a radiator to assist in cooling the receiving coil. BRIEF DESCRIPTION OF THE DRAWINGS

[0017] The above and other aspects of the present application will be more fully understood from the detailed description below in conjunction with the following drawings. It should be noted that the scales of the drawings may be different for the purpose of clarity of illustration, but this will not affect the understanding of the present application.

[0018] Figure 1 is a perspective view of an integrated wireless charging subframe according to the present application.

[0019] Figure 2 yes Figure 1 Exploded view of the integrated wireless charging subframe.

[0020] Figure 3 yes Figure 1 Another perspective view of the integrated wireless charging subframe.

[0021] Figure 4 yes Figure 1 A three-dimensional view of the charging module of the integrated wireless charging subframe. DETAILED DESCRIPTION

[0022] The following describes exemplary embodiments of the present application in more detail with reference to the accompanying drawings. Although exemplary embodiments of the present application are shown in the accompanying drawings, it should be understood that the present application can be implemented in various forms and should not be limited by the embodiments described herein. Instead, these embodiments are provided to enable a more thorough understanding of the present application and to fully convey the scope of the present application to those skilled in the art.

[0023] It should be noted that the terms "installed", "connected" and "connected" should be understood in a broad sense. For example, it can be a fixed connection, a detachable connection, or an integral connection; it can be a mechanical connection or an electrical connection; it can be a direct connection or an indirect connection through an intermediate medium, and it can be the internal connection of two components.

[0024] Figure 1 is a perspective view of an integrated wireless charging subframe according to the present application. Figure 2 yes Figure 1 Exploded view of the integrated wireless charging subframe. Figure 3 yes Figure 1 Another perspective view of the integrated wireless charging subframe. Figure 1-3As shown, the integrated wireless charging sub-frame 1 includes an upper housing 10, a lower housing 12, a radiator 14, a charging module housing 16, an anti-vibration pad 18, a charging module 20, a protective cover 22 and a connector 24. The upper housing 10 is connected to the vehicle frame (not shown) and has an opening that passes through in the vertical direction. The size of the opening of the upper housing 10 corresponds to the size of the charging module housing 16 to allow the charging module housing 16 to pass through the upper housing 10. The lower housing 12 is connected to the upper housing 10 from below and similarly has an opening that passes through in the vertical direction. The size of the opening of the lower housing 12 corresponds to the size of the charging module housing 16 to allow the charging module housing 16 to pass through the lower housing 12. The radiator 14 is provided on the bottom surface of the lower housing 12 and is composed of a plurality of heat dissipation strips that cross each other. Similarly, the radiator 14 is provided with an opening at a corresponding position with a size corresponding to the opening of the upper housing 10. The lower housing 12 is provided with grooves on the bottom surface corresponding to the heat dissipation strips of the radiator 14. The charging module housing 16 is connected to the radiator 14, specifically, is provided in the opening of the radiator 14, and extends in the vertical direction through the corresponding opening of the lower housing 12 and the corresponding opening of the upper housing 10. The charging module 20 is provided in the charging module housing 16. An anti-seismic pad 18 is provided on the inner side of the charging module housing 16 to separate the top of the charging module housing 16 and the charging module 20. A protective cover 22 is provided at the bottom of the charging module 20. The connector 24 passes through the protective cover 22 and the charging module 20 to fix the protective cover 22 to the charging module 20, and to fix the charging module 20 to the lower housing 12.

[0025] By way of example and not limitation, the upper housing 10, heat sink 14, and charging module housing 16 can be made of aluminum. The lower housing 12 can be made of plastic. The anti-vibration pad 18 can be made of rubber. Alternatively, the upper housing 10 can be made of other materials with a certain strength, such as steel or carbon fiber. Alternatively, the heat sink 14 and charging module housing 16 can be made of other materials with high thermal conductivity, such as copper.

[0026] Figure 4 yes Figure 1 A three-dimensional view of the charging module of the integrated wireless charging subframe. The charging module 20 includes a plurality of heat dissipation fins 200 provided on its outer surface. The plurality of heat dissipation fins 200 are spaced apart from each other and contact the inner wall of the charging module housing 16 at the ends to conduct the heat of the charging module 20 to the charging module housing 16. The charging module 20 also includes a controller, a temperature sensor, a power sensor and a receiving coil provided at the bottom. The temperature sensor and the power sensor are respectively connected to the controller to send the measured temperature and power of the charging module 20 to the controller. The controller adjusts the charging parameters according to the temperature and power of the charging module 20 to maintain the charging module 20 within a safe range.

[0027] When a vehicle requires wireless charging, the vehicle's electronic control unit uses various sensors to detect its location. The vehicle is then parked, either automatically or manually, in an appropriate position so that the receiving coil of the charging module 20 is aligned with the transmitting coil on the ground. When alternating current flows through the transmitting coil, it generates an oscillating magnetic field. As the current continuously changes direction (typically at a frequency of 100-200 kHz), this changing current generates a magnetic field that alternately expands and contracts. The magnetic flux lines of the magnetic field pass through the air gap between the transmitting and receiving coils. The strength of the magnetic field decreases with distance, so the receiving coil needs to be as close to the transmitting coil as possible. In the integrated wireless charging subframe according to the present application, the receiving coil of the charging module 20 is located at the bottom of the charging module 20, near the lowest point on the vehicle chassis. This allows the receiving coil to be sufficiently close to the transmitting coil on the ground, improving wireless charging efficiency. When the changing magnetic field passes through the receiving coil, it induces electron motion, generating alternating current. Since the vehicle's battery requires direct current to charge, the AC power generated by the receiving coil must be converted to direct current. This is accomplished by an inverter located in the vehicle.

[0028] The following uses a 10 kW charging power as an example to illustrate the size and configuration of the charging module 20. It will be appreciated that the charging power may vary depending on the battery size of the electric vehicle and the planned charging speed.

[0029]

[0030] In the table above, a and b represent the length and width of the receiving coil, respectively. It's understandable that since the charging power can fluctuate within a certain range, the length and width of the receiving coil can also be within a certain range (e.g., 320mm to 420mm for length and 50mm to 90mm for width).

[0031] The foregoing description of the embodiments has been provided for illustrative and descriptive purposes. It is not intended to be exhaustive or to limit the embodiments to the variations described. Many modifications and variations will be apparent to those skilled in the art. The embodiments were selected and described to best illustrate the principles and practical applications, thereby enabling those skilled in the art to understand the embodiments in their various embodiments and with various modifications as appropriate for their intended use. Within the framework of the embodiments, the components and features described above may be combined between different embodiments.

Claims

1. An integrated wireless charging subframe (1) for a vehicle, characterized in that: include: Upper housing (10); a lower housing (12) connected to the upper housing (10) from below; a heat sink (14) disposed on the bottom surface of the lower housing (12); a charging module housing (16) connected to the heat sink (14); an anti-vibration pad (18) disposed on the inner side of the charging module housing (16); a charging module (20) disposed in the charging module housing (16); and A protective cover (22) is provided at the bottom of the charging module (20).

2. The integrated wireless charging subframe (1) according to claim 1, characterized in that: The upper housing (10) is connected to the frame of the vehicle and has an opening extending therethrough in a vertical direction; and The opening of the upper housing (10) is sized to allow the charging module housing (16) to pass through the upper housing (10).

3. The integrated wireless charging subframe (1) according to claim 2, characterized in that: The lower housing (12) is provided with an opening at a position corresponding to the opening of the upper housing (10); and The opening of the lower housing (12) is sized to allow the charging module housing (16) to pass through the lower housing (12).

4. The integrated wireless charging subframe (1) according to claim 3, characterized in that: The radiator (14) comprises a plurality of radiating strips arranged in a mesh shape; The radiator (14) is provided with an opening at a position corresponding to the opening of the upper housing (10); and The opening of the heat sink (14) is sized to allow the charging module housing (16) to be positioned within the opening of the heat sink (14).

5. The integrated wireless charging subframe (1) according to claim 4, characterized in that: The lower housing (12) is provided with a plurality of grooves arranged in a mesh shape on the bottom surface thereof, corresponding to the plurality of heat dissipation strips of the heat sink (14); and The charging module housing (16) extends vertically through the opening of the lower housing (12) and the opening of the upper housing (10).

6. The integrated wireless charging subframe (1) according to any one of claims 1 to 5, characterized in that: The charging module (20) includes a plurality of heat dissipation fins (200) disposed on an outer surface thereof; and The plurality of heat dissipation fins (200) are spaced apart from each other and contact the inner wall of the charging module housing (16) at the ends to conduct the heat of the charging module (20) to the charging module housing (16).

7. The integrated wireless charging subframe (1) according to any one of claims 1 to 5, characterized in that: The charging module (20) includes a controller, a temperature sensor, a power sensor, and a receiving coil arranged at the bottom; The temperature sensor and the power sensor are respectively connected to the controller to send the measured temperature and power of the charging module (20) to the controller; as well as The controller is configured to adjust charging parameters according to the temperature and power of the charging module (20) to maintain the charging module (20) within a safe range.

8. The integrated wireless charging subframe (1) according to claim 7, characterized in that: The length of the receiving coil is in the range of 320 mm to 420 mm, and the width is in the range of 50 mm to 90 mm.

9. The integrated wireless charging subframe (1) according to any one of claims 1 to 5, characterized in that: The integrated wireless charging subframe (1) includes a connecting member (24); The connector (24) passes through the protective cover (22) and the charging module (20) to connect the protective cover (22) and the charging module (20) to the lower housing (12).

10. The integrated wireless charging subframe (1) according to any one of claims 1 to 5, characterized in that: The upper housing (10), the heat sink (14) and the charging module housing (16) are made of aluminum; The lower housing (12) is made of plastic; and The anti-vibration pad (18) is made of rubber.

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