Winding arrangement and method for manufacturing the winding arrangement

Abstract

Winding arrangement (1) for a primary part for contactless energy and / or signal transmission to a secondary part provided in an electric vehicle, comprising at least one winding made of winding wire (2) and two or more winding carriers (3, 4, 50, 90, 130, 140), where at least one winding has several turns, where at least one winding is designed as a spiral winding, wherein the distance of the winding wire (2) between adjacent turns in the direction of the winding axis changes with an increasing number of turns, wherein each winding carrier (3, 4, 50, 90, 130, 140) is connected with at least two turns and each turn is connected to at least one winding support (3, 4, 50, 90, 130, 140), wherein the winding supports (3, 4, 50, 90, 130, 140) are spaced apart from each other, wherein the turns of the at least one winding are spaced apart from each other, wherein a first turn is connected to a first of the winding supports (4, 50, 90, 130, 140), wherein the first winding is connected to the first winding support (4, 50, 90, 130, 140) at multiple points spaced apart in the circumferential direction, i.e. winding direction, wherein the winding carriers (3, 4, 50, 90, 130, 140) are each materially bonded to the windings at connection points, wherein the winding wire (2) has a cross-section completely enclosed by the material of the winding supports (3, 4, 50, 90, 130, 140) at each connection point.

Description

[0001] The invention relates to a winding arrangement and a method for its manufacture.

[0002] From DE 10 2011 110 652 A1 a method and a device for manufacturing flat coils are known.

[0003] From DE 10 2011 014 752 A1 a system for contactless energy transfer to a vehicle is known.

[0004] From US patent 2013 024 9304 A1, a wireless power transmission device and a method for its manufacture are known.

[0005] A device for contactless energy transmission is known from DE 10 2010 050 935 A1.

[0006] A method for manufacturing disc-shaped windings is known from US Patent 3,683,495 A.

[0007] From DE 10 2011 106 027 A1, a transformer component for a transmission system for charging the traction batteries of an electrically powered vehicle is known. In this component, the electrical coil arrangement of the transformer component is overmolded or cast in a flexible plastic material, and the wire windings are arranged on a flexible support frame. The support frame consists of several spaced-apart but interconnected coil carriers, each coil carrier having molded-on retaining elements for receiving a coil wire.

[0008] The invention is therefore based on the objective of further developing a winding arrangement for a primary part for contactless energy transmission to a secondary part provided in an electric vehicle and a method for its manufacture.

[0009] According to the invention, the problem is solved in the winding arrangement according to the features specified in claim 1.

[0010] Key features of the invention for the winding arrangement of a primary part for contactless energy and / or signal transmission to a secondary part provided in an electric vehicle are that the winding arrangement comprises at least one winding made of winding wire and two or more winding carriers, wherein the at least one winding has several turns, in particular several winding wire sections, wherein the at least one winding is designed as a spiral winding, in particular wherein the, in particular all, turns of the at least one winding are arranged substantially within one winding plane, wherein each winding carrier is connected to at least two turns and each turn is connected to at least one winding carrier, wherein the, in particular all, winding carriers are spaced apart from each other, and wherein the, in particular all, turns of the at least one winding are spaced apart from each other.wherein a first winding is connected to a first winding support, wherein the first winding is connected to the first winding support at multiple points spaced apart in the circumferential direction, i.e. winding direction, in particular wherein the first winding support is made in one piece, i.e. in one piece, in particular formed.

[0011] In this document, a spiral winding is understood to be a winding in which the distance of the winding wire between adjacent turns, in the direction of the winding axis, and in particular the minimum distance, changes with increasing number of turns, in particular decreases or increases monotonically, in particular where the distance of the winding wire to the winding axis increases with increasing number of turns.

[0012] The winding wire can also run in a straight line in sections, so that essentially a square spiral winding is created.

[0013] When implemented as a planar spiral winding, the spiral winding is either located in a plane, i.e., the winding plane, or, when implemented as a three-dimensional spiral winding, it corresponds to a projection of such a planar spiral winding onto a curved surface.

[0014] Circumferential direction refers to the direction along the winding wire, i.e., the winding direction.

[0015] A key advantage of this invention is its ability to enable simple and cost-effective manufacturing while maintaining increased stability. By connecting a winding to a winding support at multiple points spaced apart along its circumference, the winding wire is securely fixed in place. This makes bending, for example, perpendicular to the winding direction, more difficult. The composite component, consisting of the winding wire and winding supports, forms a pre-assembled unit for the subsequent manufacturing process. Therefore, the component can be moved in and out of storage before potential potting with potting compound without altering the spatial arrangement of the winding wire. The precise arrangement of the winding wire is crucial for achieving the most homogeneous magnetic field distribution possible.

[0016] According to the invention, the winding supports are materially bonded to the windings at connection points, with the winding wire having a cross-section completely enclosed by the winding support material at each connection point. In particular, the winding supports are injection-molded onto the windings and / or made of plastic, especially hot melt adhesive and / or thermoplastic and / or elastic material. An advantage of this is that a firm connection exists between the windings and the winding supports, preventing any displacement or slippage of the winding supports relative to the windings. Furthermore, the winding supports can be manufactured in any desired shape using a simple and cost-effective injection molding process.

[0017] In an advantageous embodiment, the winding arrangement comprises a potting compound, in particular polymer concrete, and a surface, wherein the surface is formed from at least one or more surface sections of the potting compound, and wherein the windings are arranged within and surrounded by the potting compound. It is advantageous that the space between the windings can be filled with potting compound. The composite part consisting of the winding wire and winding supports is thus permeable to the potting compound, and the winding wire is spaced apart from the outer surface of the potting compound.

[0018] In an advantageous embodiment, the winding supports each consist of at least one base body and at least one spacer rib, wherein the at least one base body is arranged within the winding assembly, i.e., spaced from the surface of the winding assembly, in particular by means of the respective spacer rib, the surface being formed from at least one or more outer surface sections of the potting compound and from respective surface sections of, in particular all, the spacer ribs. The base bodies are thus spaced from the surface of the winding assembly. The tips of the spacer ribs form part of the outer surface of the winding assembly. An advantage of this is that a defined distance between the winding wire and the outer surface of the winding assembly can be established.The spacer webs serve to position the composite part made of winding wire and winding carriers within a casting mold during the manufacturing of the winding arrangement.

[0019] In an advantageous embodiment, at least one winding support has several spacer webs, each of which is assigned to a specific turn, and in particular, the assigned spacer web is arranged closer to that turn than to any other turn. This is advantageous because the defined distance between the winding wire and the outer surface of the winding arrangement is more easily adjustable.

[0020] In an advantageous embodiment, at least one winding carrier has several base bodies, wherein the base bodies are each connected to one another via at least one spacer web and / or at least one connecting web. The advantage here is that several base bodies can be produced within a single injection molding step, and the stability of the winding arrangement is increased.

[0021] In an advantageous embodiment, at least one of the winding carriers is designed as a composite part consisting of a plastic component and at least one connecting element, in particular a threaded bushing, made of metal, especially aluminum or stainless steel. The connecting element has a section that borders an opening in the connecting element and forms part of the surface of the winding arrangement. The opening of the connecting element is thus located on the surface of the winding arrangement and is accessible from the outside. It is advantageous that the winding arrangement can be easily connected, in particular by screwing, to ferrite plates and / or aluminum plates and / or to a support plate.

[0022] In an advantageous embodiment, the connecting element is positively connected to the winding carrier and / or the connecting element is narrower on the surface of the winding carrier than in the interior of the winding carrier, particularly in an area spaced from the surface of the winding carrier within the winding carrier, and / or the connecting element has a barbed section and / or an anchor section inside the winding carrier. The advantage here is that the connection between the connecting element and the winding carrier is stable and prevents the connecting element from easily coming loose.

[0023] In an advantageous embodiment, at least one winding carrier is designed as a composite component consisting of a plastic part and an antenna for positioning an electric vehicle and / or for communication with an electric vehicle. The antenna is metallurgically bonded to the winding carrier, in particular, the winding carrier being injection-molded onto the antenna. The antenna is completely or partially enclosed by the winding carrier. The antenna consists of several metallic windings, in particular, the antenna windings being implemented as conductor tracks on a printed circuit board. An advantage of this design is the simplified manufacturing process. The antenna is connected to the winding wire via a winding carrier during the injection molding process, thus determining its spatial position relative to the winding wire. This eliminates the need for a separate alignment step during subsequent potting with potting compound.Preferably, the printed circuit board has recesses, in particular four recesses.

[0024] In an advantageous embodiment, the winding arrangement comprises reinforcing bars, particularly those made of glass fiber reinforced plastic, wherein the reinforcing bars are partially surrounded along their longitudinal direction by at least a portion of one or more winding carriers. This is advantageous because it increases the stability of the winding arrangement. The reinforcing bars are connected to the winding wire via at least one winding carrier during the injection molding process, thus determining their spatial position relative to the winding wire. This eliminates the need for a separate alignment step during the subsequent potting process.

[0025] In an advantageous embodiment, the surface of the winding arrangement has several partial surfaces, and at least one winding support has at least two spacer webs, wherein at least two spacer webs of each winding support partially form surface sections of different partial surfaces. It is advantageous that a defined distance between the winding wire and the respective partial surfaces can be established.

[0026] In an advantageous embodiment, a portion of the winding arrangement's surface is curved, in particular corresponding to a spherical section or an elliptically paraboloid section. The advantage here is that liquid can flow off the curved surface. A convex curvature is particularly advantageous, as it ensures drainage regardless of the mounting direction.

[0027] In an advantageous embodiment, the winding wire of at least one winding is designed as a stranded wire, in particular wherein the stranded wire is designed as a bundle of electrically insulated individual wires. The advantage here is that low losses occur. Advantageously, high-frequency stranded wire is used.

[0028] The process for manufacturing a winding arrangement comprises the following steps: (i) Inserting the at least one winding into a first one-piece or multi-piece injection mold, (ii) Manufacturing winding carriers by overmolding parts of the windings with plastic, in particular so that a composite part of windings and winding carriers is produced, (iii) Removal of the injection mold, especially after cooling and solidification of the hot melt adhesive, (iv) Inserting the at least one winding and the winding carrier into a casting tool, in particular inserting the composite part into a casting tool, (v) Potting, in particular at least partially carried out, of the at least one winding and the winding carrier with potting compound.

[0029] The advantage here is that the process is simple and cost-effective. Because the composite component consisting of winding wire and winding supports is permeable to potting compound, increased stability of the winding arrangement is ensured.

[0030] In an advantageous embodiment, the mold is made up of at least two parts. This is advantageous because it allows for simplified positioning of the winding and the winding support, particularly the composite part, within the mold. In a particularly advantageous embodiment, the composite part consisting of the winding wire and winding support is positioned in the first part of the mold. The second part of the mold is then placed over the composite part.

[0031] According to the invention, one or more winding carriers have one or more spacer sections, wherein the casting mold has recesses, in particular cutouts, for partially receiving the spacer sections, wherein in step (iv) the composite part is positioned and / or aligned at the recesses by means of the spacer sections.

[0032] An advantage of this is that precise positioning of the winding and the winding carrier, especially the composite part, is possible within the casting mold.

[0033] In an advantageous embodiment, the mold is cup-shaped, particularly in which the potting compound is poured into the mold parallel to the winding plane. An advantage of this is that, during assembly, the top and bottom surfaces of the winding arrangement have a smooth and defined surface.

[0034] In an advantageous embodiment, the casting mold is trough-shaped, in particular wherein the casting compound (60) is poured into the casting mold (150) parallel to the normal direction of the winding plane. An advantage of this is that simple manufacturing is enabled.

[0035] Further advantages arise from the sub-claims.

[0036] The invention will now be explained in more detail with the help of illustrations: In the Fig. Figure 1 shows a schematic top view of a winding arrangement according to the invention. In the Fig. Figure 2 shows a schematic view of an exemplary winding arrangement with two partial windings in top view. In the Fig. Figure 3 shows a schematic view of another exemplary winding arrangement with two partial windings in top view. In the Fig. Figure 4 shows a schematic view of another exemplary winding arrangement with two partial windings in top view, omitting the representation of all actually existing winding carriers. In the Fig. Figure 5 shows a schematic view of another winding arrangement according to the invention with two partial windings in a top view, whereby the representation of all actually existing winding carriers has been omitted. In the Fig. Figure 6 shows an exemplary winding arrangement in top view. In the Fig. 7 is the winding arrangement made of Fig. 6 shown in sectional view. In the Fig. Figure 8 shows another winding arrangement according to the invention in sectional view. In the Fig. Figure 9 shows another winding arrangement according to the invention in a top view. In the Fig. 10 is the winding arrangement according to the invention made of Fig. 9 shown in sectional view. In the Fig. Figure 11 shows another exemplary winding arrangement in top view. In the Fig. 12 is the winding arrangement made of Fig. 11 shown in sectional view. In the Fig. Figure 13 shows a top view of a part of another winding arrangement according to the invention. In the Fig. Figure 14 shows a top view of part of another winding arrangement according to the invention. The Fig. Figure 15 schematically shows a winding arrangement according to the invention and an associated casting mold in sectional view. The Fig. Figure 16 schematically shows another winding arrangement according to the invention and an associated casting mold in sectional view. The Fig. Figure 17 schematically shows another winding arrangement according to the invention and an associated casting mold in sectional view. The Fig. Figure 18 schematically shows another winding arrangement according to the invention and an associated casting mold in sectional view. The Fig. Figure 19 schematically shows another winding arrangement according to the invention and an associated casting mold in sectional view. The Fig. Figure 20 schematically shows another winding arrangement according to the invention in sectional view.

[0037] Exemplary embodiments of the invention are explained below with reference to the accompanying drawings, whereby the same reference numerals are used for parts that act identically and are not described again with each figure.

[0038] As in the Fig. As shown in Figure 1, the winding arrangement (1) consists of a winding of winding wire (2) and several winding supports (3,4) which are spaced apart from each other in the circumferential direction, i.e. in the winding direction.

[0039] The winding has ten turns and is designed as a flat winding. The winding wire (2) therefore lies in a plane, which is also referred to as the winding plane. Adjacent turns are spaced apart from each other; they do not touch. In this embodiment, the distance between two adjacent turns is always the same. However, other distances are also conceivable, for example, from the inside to the outside, in particular monotonically increasing or decreasing distance values.

[0040] In this document, the direction perpendicular to the winding plane is referred to as the winding axis. The flat winding is designed such that, viewed radially to the winding axis, the distance between the corresponding winding wire section of the turn and the winding axis increases with each turn, thus forming a spiral winding. In the exemplary embodiment of the Fig. Figure 1 shows the spiral winding with straight and rounded winding sections.

[0041] The winding wire (2) of the winding arrangement forms a primary winding for contactless energy and / or data transmission to a secondary winding provided in an electric vehicle. The primary winding is part of a primary section for inductive, i.e., contactless, charging of an energy storage device provided in an electric vehicle.

[0042] The winding supports (3, 4) are made of hot melt adhesive and are injection-molded onto the plastic sheath of the winding wire. The individual winding supports (3, 4) are therefore bonded to the turns of the winding wire (2).

[0043] The winding supports (3, 4) serve to fix the winding wire (2) in its spatial arrangement to such an extent that a simplified manufacturing of the winding arrangement (1) is possible. Therefore, each winding support (3, 4) is connected to at least two turns.

[0044] In the exemplary embodiment of the Fig. Figure 1 shows two types of winding carriers (3,4).

[0045] In this embodiment, the winding supports (3) of the first type are arranged on the straight sections of the winding, while the winding supports (4) of the second type are arranged on the curved deflection sections of the winding. The curved deflection sections are quarter-circle shaped.

[0046] The winding support (3) of the first type is rod-shaped, so its thickness is much smaller compared to its length. The winding support (3) of the first type is connected with at least two turns at at most one point, i.e., connection point.

[0047] In the exemplary embodiment of the Fig. In the first embodiment, the winding supports (3) are connected to each turn exactly once and are oriented within the winding plane such that their length is perpendicular to the winding direction. In further embodiments according to the invention, the winding supports (3) are connected to only a portion of the turns and / or the orientation of the length of the winding support (3) is not perpendicular to the winding direction.

[0048] The winding support (4) of the second type has a fir tree-like structure with a trunk (5) and branches (6). The trunk (5) and branches (6) are each designed as rod-shaped sections and are referred to below as the main body (5) and side arms (6). The main body (5) is oriented within the winding plane such that its length runs perpendicular to the winding direction of the corresponding wire section at the connection point. The side arms (6) extend from both sides of the main body within the winding plane at a 45° angle.

[0049] Both the main body (5) and the side arms (6) are connected to each winding at most once. The winding support (4) of the second type is thus connected to the respective windings at multiple points spaced apart in the circumferential direction, i.e., in the winding direction, i.e., connection points. For example, the outermost winding has seven connection points to a winding support (4) of the second type. A connection point is understood to be the region of space in which a winding wire segment and a winding support are in contact. The connection point is therefore a region of space that extends, in particular, in the circumferential direction. Between two adjacent and spaced connection points, there is only the corresponding winding wire segment in the circumferential direction, and therefore, in particular, no material of the winding support.

[0050] The winding carriers (3,4) are all manufactured in one piece. They are produced in a single injection molding process step.

[0051] For all winding supports (3, 4), the material of the winding supports at the connection point completely encloses the winding wire of the corresponding turn in a ring-like manner. Thus, at each connection point, the winding wire has a cross-section that is completely enclosed by the material of the winding supports (3, 4, 50, 90, 130, 140).

[0052] At the in Fig. In the alternative embodiment shown in Figure 2, the winding arrangement (1) consists of two partial windings (20, 21), each having the same wound area and the same number of turns, but opposite winding directions. Both partial windings are designed as flat spiral windings.

[0053] The winding arrangement (1) has exclusively winding carriers (3) of the first type, which for the sake of simplicity are referred to below as Fig. 2 shall be referred to simply as winding supports (3). The winding supports (3) of each partial winding are spaced apart from each other in the circumferential direction and are arranged both on the straight sections and on the curved deflection areas.

[0054] The winding carriers (3) are oriented within the winding plane such that their length at the connection point is perpendicular to the winding direction.

[0055] The number of connection points varies for individual winding carriers (3). For example, the winding carriers (3) at the curved deflection sections are only connected to a portion of the turns, whereas the winding carriers at the straight sections are connected to all turns. Where the two partial windings (20, 21) are adjacent, the winding carriers are connected to all turns of both partial windings.

[0056] During the Fig. In the further embodiments shown in Figures 3 to 5, the winding arrangement also consists of two partial windings (20, 21), each of which has the same wound area and the same number of turns, but opposite winding direction.

[0057] The two partial windings (20, 21) of the Fig. Figures 3 to 5 are each schematically drawn as a set of nested, rounded rectangles. These schematically represent the in Fig. 2 shown plane spiral windings.

[0058] The winding arrangements (1) of the Fig. 3 and Fig. Each of the 4 components has exclusively winding carriers (3) of the first type, which, for the sake of simplicity, will henceforth be referred to simply as winding carriers (3). The winding carriers (3) are spaced apart from each other and are arranged both on the straight sections and on the curved deflection sections of the two partial windings (20, 21).

[0059] At the in Fig. In the winding arrangement shown (1) 3, the number of connection points for individual winding carriers (3) varies. However, each winding carrier (3) is connected to at least two, and in particular at least three, turns of the first partial winding (20) and / or second partial winding (21). The winding carriers (3) are oriented within the winding plane such that their length at the connection point is perpendicular to the winding direction.

[0060] At the in Fig. In the winding arrangement shown in 4 (1), each winding carrier is in turn connected to at least two turns of the first partial winding (20) or second partial winding (21). In the Fig. Figure 4 does not show all the winding carriers that are actually present, but only the winding carriers for one area of ​​the winding arrangement.

[0061] The winding supports (3) are oriented within the winding plane such that their length at the connection point is not perpendicular, but oblique to the winding direction. On the straight sections of the partial windings (20, 21), two next-but-one winding supports (3) are arranged parallel to each other along their length.

[0062] The in Fig. The winding arrangement (1) shown in Figure 5 has, in addition to winding supports (3) of the first type, also winding supports (50) of the third type, which are arranged on the straight sections of the partial windings (20, 21) and are composed of several rod-shaped sections (51). In the Fig. Figure 5 does not show all the winding carriers that are actually present, but only the winding carriers for one area of ​​the winding arrangement.

[0063] The rod-shaped sections (51) each lie in the winding plane. Two next-but-one rod-shaped sections (51) are arranged parallel along their length, thus forming a zigzag structure.

[0064] The winding support (50) of the third type is connected to the respective windings at multiple connection points spaced apart in the circumferential direction, i.e., the winding direction. The number of rod-shaped sections of the winding support (50) of the third type is variable, as shown by Fig. 5 for example a winding carrier (50) of the third type with three and one with nine rod-shaped sections (51).

[0065] The winding arrangement (1) of the Fig. 6, in addition to the winding wire (2) of the winding and the winding supports (3) of the first type, hereinafter referred to simply as winding supports (3), also includes casting compound (60) made of polymer concrete.

[0066] The winding wire (2) of the winding, including the winding supports (3), is completely surrounded by the potting compound (60). The space between the individual turns is also filled with potting compound (60).

[0067] In further embodiments of the invention, the casting compound consists of concrete or reactive resin with additional fillers and / or additives. In principle, any castable material is suitable as a casting compound.

[0068] Fig. Figure 7 shows a sectional view of the winding arrangement (1) from Fig. 6. The cutting plane is in Fig. 6 indicated by arrows.

[0069] The winding carriers (3) each consist of a base body (70) and spacer webs (71). The winding wire (2) is completely surrounded by the base body (70) in a ring-shaped manner in the section plane.

[0070] The spacer webs (71) enable the winding device (1) to be manufactured in such a way that the winding wire (2) and the base bodies (70) have a defined distance from the outer surface of the potting compound (60).

[0071] In this embodiment, the surface of the winding assembly (1) is formed by the respective surface sections of the spacer webs (71) and the outer surface sections of the potting compound (60). Thus, both the winding wire (2) and the base bodies (70) of the winding supports (3) are spaced from the surface of the winding assembly (1). In this example, the surface of the winding assembly (1) is cuboid in shape.

[0072] The individual winding carriers (3) are manufactured using an injection molding process. Each winding carrier is therefore manufactured in one piece, meaning that the base body (70) and the complaint ribs (71) are contained in one piece.

[0073] To form a primary component for the inductive, i.e., contactless, charging of an electric vehicle, it is advantageous to arrange a ferrite layer (72) and an aluminum layer (73) on the underside of the winding assembly (1). The layers are each designed as solid plates. The ferrite layer (72) consists of ferrite plates and foils, with the ferrite plates being bonded to a foil on both sides. For improved mechanical stabilization, the winding assembly (1), ferrite layer (72), and aluminum layer (73) are in turn arranged on a support (74), which is also made of potting compound (60), in particular polymer concrete. The individual components are bonded together, i.e., materially connected.

[0074] Fig. Figure 8 shows an alternative winding arrangement (1) according to the invention in sectional view. The winding carriers (3) shown here each consist of a base body (70), three spacer webs (71) and a connecting element (80).

[0075] The connecting element (80) is designed as a metallic threaded bushing. The winding carrier (3) is designed as a composite part consisting of a plastic part (70, 71) and a metallic connecting element (80). The connecting element (80) is positively connected to the winding carrier (3).

[0076] The connecting element (80) has an opening which is bordered by a section of the connecting element. This section forms part of the surface of the winding arrangement (1), in addition to the outer surface sections of the potting compound (60) and the respective sections of the spacer webs.

[0077] As in Fig. As shown in Figure 8, the connecting element (80) on the surface of the winding carrier (3) is less wide than inside the winding carrier (3), in particular than in an area inside the winding carrier spaced apart from the surface of the winding carrier (3).

[0078] In an alternative embodiment, the connecting element (80) has a barbed section and / or anchor section inside the winding carrier (3). This prevents the connecting element (80) from detaching from the winding carrier (3).

[0079] In this embodiment, the surface of the winding assembly (1) is formed by the outer surface of the potting compound (60), as well as by the outer surface sections of the spacer webs (71) and the connecting elements (80). The base bodies (70) and the winding wire (2) are spaced apart from the surface of the winding assembly (1).

[0080] The connecting elements (80) integrated into the winding arrangement (1) make it possible to easily connect the other components of the primary part, such as the ferrite layer (72), the aluminum layer (73), and the carrier (74), by means of a fastening element (81), in particular by force-fit or form-fit. In this embodiment, the fastening element (81) is designed as a screw.

[0081] In the Fig. Figure 9 shows an alternative winding arrangement (1) according to the invention in a top view. In addition to winding carriers (3) of the first type, this arrangement also includes a winding carrier (90) of the fourth type. This winding carrier (90) consists of six outer base bodies (91), each of which has a connecting web (92) leading to a central base body (93). The central base body, in turn, surrounds an antenna (94) that belongs to a system for positioning an electric vehicle and / or for communication with an electric vehicle. The antenna has a secondary winding on its underside, which is inductively coupled to the flat winding and thus can be supplied with electrical power inductively, i.e., without contact, in particular for charging an energy storage device of the vehicle. The antenna (94) is connected to an electronic circuit that generates the signals to be transmitted for positioning and / or data transmission.

[0082] The antenna consists of several metallic windings, with the antenna windings implemented as conductive traces on a printed circuit board. In this embodiment, the printed circuit board has four rectangular cutouts.

[0083] The Fig. Figure 10 shows a corresponding sectional view of the design. Fig. 9. The cutting plane is in Fig. 9 indicated by arrows.

[0084] Both the outer (91) and the middle base body (93) of the winding support (90) of the fourth type have spacer webs (71) so that the winding wire (2) and the antenna (94) have a defined distance from the surface of the winding assembly (1). In this embodiment, the surface of the winding assembly (1) is formed by the outer surface of the potting compound (60) and the outer surface sections of the spacer webs (71).

[0085] In the exemplary embodiment of the Fig. The winding arrangement (1) comprises reinforcing bars (110) made of glass fiber reinforced plastic. The reinforcing bars (110) form a grid within the casting compound (60), which ensures increased mechanical stability. The reinforcing bars (110) are partially and completely encapsulated in plastic and are therefore materially and form-fittingly connected to the base bodies (70) of the winding carriers (3) of the first type.

[0086] The Fig. Figure 12 shows a corresponding sectional view of the design. Fig. 11. The cutting plane is in Fig. 11 indicated by arrows.

[0087] The base bodies (70) of the winding carriers (3) of the first type again have spacer webs (71) so that the winding wire and the reinforcing bars (110) have a defined distance from the surface of the winding arrangement (1). In this embodiment, the surface of the winding arrangement (1) is formed by the outer surface of the potting compound (60) and the outer surface sections of the spacer webs (71).

[0088] In the Fig. Figure 13 shows a winding carrier (130) of the fifth type, which consists of several base bodies (70). A thin connecting web (92) extends from each of the base bodies (70). All connecting webs (92) terminate at a common connection point, which is also referred to as the injection point (131).

[0089] Advantageously, during the manufacturing process, the liquid plastic is injected at the injection point (131), so that several base bodies (70) can be produced in one manufacturing step.

[0090] In the Fig. Figure 14 shows winding carriers (140) of the sixth type, which consist of two base bodies (70). The base bodies (70) are connected to each other by spacer webs (71). The spacer webs (71) of the winding carriers enable the positioning of the winding wire (2) within a casting tool (150) for the production of the winding arrangement (1), as will be shown later with reference to Fig. 15 is explained.

[0091] The following describes the procedure for manufacturing the winding arrangement (1).

[0092] First, the winding wire (2) is placed into an injection mold (not shown). This injection mold has recesses for the winding wire (2) as well as recesses for the winding supports (3, 4, 50, 90, 130, 140). The injection mold is made of two parts. However, in other embodiments, one-piece or multi-part versions of the injection mold are also possible.

[0093] After the winding wire (2) is placed in the injection mold and the at least two parts of the injection mold are joined, the hot, liquid hot melt adhesive is injected into openings in the injection mold to form the winding supports. The winding supports are thus produced by overmolding sections of the windings with hot melt adhesive.

[0094] After the plastic has cooled and solidified, the injection mold is removed. The product of the injection molding process is a composite part made up of windings and winding carriers.

[0095] The winding wire (2) with molded-on winding carriers (3, 4, 50, 90, 130, 140), i.e. the composite part, is then, as in Fig. 15 schematically depicted, placed in a casting mold (150). In the exemplary embodiment of the Fig. 15 The winding carriers (3) of the first type have both spacer webs (71) perpendicular to the winding plane and those parallel to the winding plane. This enables a defined positioning of the winding wire (2) within the casting mold (150).

[0096] The casting mold (150) in the exemplary embodiment of the Fig. 15 is designed as a cuboid open at the top, i.e., against the direction of gravity. It is thus designed in a trough shape to allow the pouring of liquid casting compound (60). Trough-shaped is defined as a container having an opening, particularly directed upwards, and a depth, wherein the spatial extent of the opening in every direction within the plane of the opening is greater in magnitude, and in particular much greater, than the depth of the container.

[0097] In the exemplary embodiment of the Fig. 15. The potting compound (60) is poured in essentially parallel to the normal direction of the winding plane. The potting compound encloses the windings and at least partially the winding supports (3). The surface of the manufactured winding assembly is formed by the potting compound and portions of the spacer webs (71).

[0098] After the casting compound (60) has been poured and solidified, the mold (150) is removed. The opening of the mold (150) remains open during the solidification process of the casting compound (60). If necessary, the surface must be smoothed after pouring the casting compound (60).

[0099] While in the exemplary embodiment of the Fig. 15. The filling of the potting compound (60) is carried out parallel to the normal direction of the winding plane; in the exemplary embodiment of the Fig. 16 The potting compound (60) is poured in parallel to the winding plane. Here, the mold is also designed as an upwardly open cuboid; however, it is cup-shaped. Cup-shaped is defined as a container having an opening, particularly directed upwards, and a depth, wherein the spatial extent of the opening in at least one direction within the plane of the opening is smaller in magnitude, in particular much smaller, than the depth of the container.

[0100] The winding wire (2) together with the winding supports (3, 4, 50, 90, 130, 140) is inserted into the mold (150) parallel to the winding plane. The opening of the mold (150) is not closed during the solidification process and may need to be smoothed before solidification. The surface to be air-dried is shown in the exemplary embodiment of the Fig. 16 less than in the exemplary embodiment of the Fig. 15.

[0101] In the exemplary embodiment of the Fig. 17. The potting compound (60) is also poured parallel to the winding plane of the winding wire (2). Additional spacer sections (170), which are part of the respective winding carriers (3, 4, 50, 90, 130, 140), serve to position the winding wire (2). The winding carriers (3, 4, 50, 90, 130, 140) thus have spacer sections (170). The spacer sections engage in corresponding recesses of the mold (150), so that displacement parallel to the winding plane is not possible. The composite part is therefore positioned, i.e., aligned, by means of the spacer sections at the recesses.

[0102] In order for the winding wire (2) with the winding carriers (3, 4, 50, 90, 130, 140) to be inserted into the casting mold (150), the mold must be multi-part, for example two-part as in Fig. 17 shown, executed.

[0103] Fig. Figure 18 shows a similar embodiment as Fig. 15. Here too, the potting compound (60) is poured in perpendicular to the winding plane. However, no spacer ribs (71) are used here to position the winding wire (2) parallel to the winding plane, as in Fig. 15, but spacer sections (170) which engage in corresponding recesses of the casting mold tool (150).

[0104] In Fig. Figure 19 shows a further embodiment. The casting mold (150) is also trough-shaped, but its inner surface is not flat but curved, in particular corresponding to a spherical section or an elliptically paraboloid section. After the casting compound (60) has been poured in and solidified, the casting mold (150) is removed and the winding arrangement (1) is rotated so that the curved surface faces upwards. This is shown in Fig. 20 shown.

[0105] In further embodiments according to the invention, the winding carriers of the winding arrangement (1), which has a curved partial surface, also have spacer webs (71). Reference symbol list 1 Winding arrangement 2 windings 3 winding carriers of the first type 4 winding carriers of the second type 5 Main body of the winding carrier (4) of the second kind 6 Side arm of the winding carrier (4) of the second kind 20 First partial winding 21 Second partial winding 50 winding carriers of the third type 51 Rod-shaped section of a winding carrier (50) of the third kind 60 potting compound 70 Base body of a winding carrier (3, 4, 50, 90, 130, 140) 71 Spacing Bridge 72 Ferrite layer 73 Aluminum layer 74 carriers 80 Connecting element 81 Fasteners 90 winding carriers of the fourth type 91 Outer base body of a winding carrier (90) of the fourth kind 92 Connecting bridge 93 Middle base body of a winding carrier (90) of the fourth kind 94 Antenna 110 reinforcing bars 130 winding carriers of the fifth type 131 Injection point 140 winding carriers of the sixth type 150 casting mold tools 170 spacer section

Claims

[1] Winding arrangement (1) for a primary part for contactless energy and / or signal transmission to a secondary part provided in an electric vehicle, comprising at least one winding made of winding wire (2) and two or more winding carriers (3, 4, 50, 90, 130, 140), where at least one winding has several turns, where at least one winding is designed as a spiral winding, wherein the distance of the winding wire (2) between adjacent turns in the direction of the winding axis changes with an increasing number of turns, wherein each winding carrier (3, 4, 50, 90, 130, 140) is connected with at least two turns and each turn is connected to at least one winding support (3, 4, 50, 90, 130, 140), wherein the winding supports (3, 4, 50, 90, 130, 140) are spaced apart from each other, wherein the turns of the at least one winding are spaced apart from each other, wherein a first turn is connected to a first of the winding supports (4, 50, 90, 130, 140), wherein the first winding is connected to the first winding support (4, 50, 90, 130, 140) at multiple points spaced apart in the circumferential direction, i.e. winding direction, wherein the winding carriers (3, 4, 50, 90, 130, 140) are each materially bonded to the windings at connection points, wherein the winding wire (2) has a cross-section completely enclosed by the material of the winding supports (3, 4, 50, 90, 130, 140) at each connection point. [2] Winding arrangement (1) according to claim 1, characterized by, that the winding carriers (3, 4, 50, 90, 130, 140) are injection-molded onto the windings and / or wherein the winding carriers (3, 4, 50, 90, 130, 140) are made of plastic. [3] Winding arrangement (1) according to claim 1 or 2, characterized by , that the winding arrangement (1) potting compound (60) and a surface wherein the surface is formed from at least one or more surface sections of the potting compound (60) and wherein the windings are arranged within and surrounded by the potting compound (60). [4] Winding arrangement (1) according to claim 3, characterized by , that the winding carriers (3, 4, 50, 90, 130, 140) each consist of at least one base body (70, 91, 93) and at least one spacer web (71), wherein the at least one base body (70, 91, 93) is arranged within the winding arrangement (1), i.e., is spaced away from the surface of the winding arrangement (1), wherein the surface is formed from at least one or more outer surface sections of the potting compound (60) and from respective surface sections of the spacer webs (71). [5] Winding arrangement (1) according to claim 4, wherein at least one winding carrier (3, 4, 50, 90, 130, 140) has several spacer webs (71). [6] Winding arrangement (1) according to claim 4 or 5, characterized by , that at least one winding carrier (3, 4, 50, 90, 130, 140) has several base bodies (70, 91, 93), wherein the basic bodies (70, 91, 93) are each connected to each other via at least one spacer web (71) and / or via at least one connecting web (92). [7] Winding arrangement (1) according to any one of claims 3 to 6, characterized by , that at least one of the winding carriers (3, 4, 50, 90, 130, 140) as a composite part made of a plastic part (70, 71, 91, 92, 93, 131, 170) and at least one connecting element (80) is made of metal wherein the at least one connecting element (80) has a section, wherein the section borders an opening of the at least one connecting element (80), wherein the section forms part of the surface of the winding arrangement (1). [8] Winding arrangement (1) according to claim 7, characterized by , that the connecting element (80) is positively connected to the winding carrier (3, 4, 50, 90, 130, 140). and / or the connecting element (80) on the surface of the winding carrier (3, 4, 50, 90, 130, 140) is less wide than inside the winding carrier (3, 4, 50, 90, 130, 140) and / or the connecting element (80) has a barbed section and / or armature section inside the winding carrier (3, 4, 50, 90, 130, 140). [9] Winding arrangement (1) according to any one of claims 3 to 8, characterized by , that at least one winding carrier (3, 4, 50, 90, 130, 140) is designed as a composite part consisting of a plastic part (70, 71, 91, 92, 93, 131, 170) and an antenna (94) for positioning an electric vehicle and / or for communication with an electric vehicle. [10] Winding arrangement (1) according to any one of claims 3 to 9, characterized by , that the winding arrangement (1) has reinforcing bars (110), wherein the reinforcing bars (110) are surrounded in their longitudinal direction section by at least a partial area of ​​one or more winding carriers (3, 4, 50, 90, 130, 140). [11] Winding arrangement (1) according to any one of claims 4 to 10, characterized by , that the surface of the winding arrangement (1) has several partial surfaces and at least one winding support (3, 4, 50, 90, 130, 140) has at least two spacer webs (71), wherein at least two spacer webs (71) of a respective winding carrier (3, 4, 50, 90, 130, 140) partially form surface sections of different subsurfaces. [12] Winding arrangement according to at least one of the preceding claims, characterized by , that the winding wire (2) of which at least one winding is designed as a stranded wire. [13] Method for manufacturing a winding arrangement (1) according to at least one of claims 1 to 12 comprising the following steps: (i) Inserting the at least one winding into a first one-piece or multi-piece injection mold, (ii) Manufacturing winding carriers (3, 4, 50, 90, 130, 140) by overmolding partial areas of the windings with plastic, so that a composite part of windings and winding carriers (3, 4, 50, 90, 130, 140) is produced, (iii) Removal of the injection mold, (iv) Inserting the composite part into a casting mold (150), (v) at least partially completed overmolding of the composite part with casting compound (60), wherein one or more winding carriers (3, 4, 50, 90, 130, 140) has or have one or more spacer sections (170), wherein the casting mold (150) has recesses for the partial reception of the spacer sections (170), wherein in step (iv) the composite part is positioned and / or aligned at the recesses using the spacer sections (170).

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