ELECTRICAL UNIT IN HOUSING MADE OF DIFFERENT MATERIALS

Description

[0001] The present invention relates to an electrical unit for motor vehicles.

[0002] The invention is described with reference to a component of a charging system or an electrical charging system for motor vehicles. In particular, this electrical unit contains at least one coil that is suitable and intended for transmitting electrical energy by inductive means. However, it should be noted that the present invention can also be applied to other electrical units, in particular electrical units that are subject to difficult environmental conditions during operation, such as vibrations, strong temperature fluctuations, and the like. Various units housed in housings are known from the prior art. However, for units that are to be attached to external surfaces, for example to the undersides of motor vehicles, a number of additional criteria must be observed.The susceptibility of such components to vibrations, as well as to splash water and dirt, must be reduced. Furthermore, such components must also be able to withstand high temperatures and significant temperature fluctuations.

[0003] DE 10 2012 223354 A1 shows an electrical unit with the features of the preamble of claim 1.

[0004] The present invention is therefore based on the object of providing an electrical component which in particular satisfies the above-mentioned criteria. An electrical component according to the invention for motor vehicles is defined in claim 1 and has a housing within which at least one electrical component is arranged. Furthermore, the component has an interface which is preferably located at least partially outside the housing and which enables electrically conductive contact or connection of this component. The housing has a first housing part and a second housing part which are fastened to one another with at least one fastening means. These housing parts extend at least along a longitudinal direction and along a width direction perpendicular to this longitudinal direction.

[0005] According to the invention, the first housing part and the second housing part are made of different materials. By manufacturing them from different materials, different expansions of the two materials can be compensated. One of the two materials can be suitable for enabling induction through this respective housing part, for example, with other components. In particular, a housing part can be suitable and intended not to impede a magnetic flux.

[0006] An electrical component is understood to be a component that is particularly powered by electrical energy and / or that is suitable for conducting electrical currents and / or electrical and / or magnetic fields. These can be active electrical components, such as semiconductor elements, as well as passive electrical components, such as resistors, coils, ferrite bodies, and the like.

[0007] Preferably, one of the two materials can also be designed in such a way that it allows a good temperature flow, so that heat dissipation and / or thus cooling of the component is possible.

[0008] The fastening means for arranging the assembly on the motor vehicle, and in particular on a frame region of the motor vehicle, can preferably be one or more screw means. These screw means can preferably be arranged on one of the two housing parts. These fastening means and / or screw means preferably extend through the respective other housing part or a region thereof.

[0009] In a preferred embodiment, the housing or the two housing parts extend significantly further or longer in the longitudinal and width directions than in a vertical direction perpendicular thereto. Thus, the housing is preferably designed as a relatively flat, in particular approximately cuboid-shaped housing. Advantageously, the housing parts and / or the assembled housing have rounded corners. In a further preferred embodiment, the surfaces of the housing are advantageously smooth. In this way, wind resistance of the housing can be kept low.

[0010] In other words, the surface of at least one housing part, for example, an aluminum housing part, and also of the other housing part, such as a plastic housing part, is smooth to reduce driving noise. Any openings that are present or required here, for example, for screwing and / or connecting, are preferably closed. All edges are preferably rounded as mentioned above.

[0011] In a further advantageous embodiment, at least one housing part is made of a plastic material. In a further advantageous embodiment, at least one housing part is made of a metal material. Preferably, the housing part made of the plastic material is the housing part opposite which, in a charging state, another coil, such as a permanently installed or stationary charging coil, is located. This means that the charging process takes place through the plastic housing or the plastic housing part. The metal is preferably aluminum.

[0012] In a further advantageous embodiment, the interface is arranged on exactly one housing part, and in particular on the metal housing part. In a preferred embodiment, the interface, for example a plug-in element, is designed such that plug connections can be integrated directly into an aluminum housing part. This can be achieved by appropriately designing the aluminum housing part.

[0013] In this way, for example, an additional flange can be dispensed with.

[0014] In a further preferred embodiment, the coil device is arranged in at least one housing part, and in particular in the housing part made of a plastic. Therefore, this housing part preferably has a receiving area for receiving the coil device. This receiving area is preferably designed such that the entire coil device can be accommodated in this housing part.

[0015] Preferably, the coil device is fixed relative to the first housing part. Preferably, the coil device is fixed exclusively relative to the first housing part and, particularly preferably, is not in contact with the second housing part.

[0016] In a preferred embodiment, at least one housing part, and preferably the housing part made of plastic, serves to accommodate a ferrite body. Particularly preferably, holding devices are provided which fix the ferrite body relative to this housing part and, in particular, fix it exclusively relative to this housing part. Preferably, the ferrite body does not contact this housing part. Here, too, a defined position of the ferrite body relative to this housing part is preferably achieved by a corresponding structural design of the housing part.

[0017] In a further advantageous embodiment, a fastening means is arranged on at least one housing part for attaching the electrical assembly to the motor vehicle. In particular, the fastening means are provided for attaching the housing part and in particular the entire assembly to an exterior of the motor vehicle, for example, to a frame element. In particular, the assembly can be attached to an underside of the vehicle.

[0018] In a preferred embodiment, a plurality of fastening means are arranged on at least one housing part. These fastening means are preferably designed in the form of pins or screws and preferably extend in a thickness direction of the structural unit or perpendicular to the longitudinal and width directions. These fastening means or projections can be designed such that they extend through openings or holes in the respective other housing part. Thus, a plurality of circumferential fastening means can be provided, by means of which the structural unit is attached to the motor vehicle.

[0019] In a preferred embodiment, the at least one fastening means and preferably these multiple fastening means are arranged at the edge of the housing. These fastening means are particularly preferably arranged along an outer circumference of the housing. Preferably, the at least one fastening means is rotatable, and in particular rotatable relative to a longitudinal direction of the fastening means relative to at least one housing part, and preferably relative to both housing parts.

[0020] In a preferred embodiment, at least one of these fastening means has an external thread. In a further preferred embodiment, the device has at least two such fastening means, preferably at least four such fastening means.

[0021] Preferably, at least one housing part serves to dissipate waste heat and thus indirectly cool the respective electrical components. For example, the entire system can be cooled using passive cooling. Alternatively, however, the system can also be cooled using active cooling, for example, by integrating a cooling circuit. The metal or aluminum housing part can be equipped or implemented with either a passive cooling function or an active cooling function.

[0022] In a preferred embodiment, the metallic housing part, for example, the aluminum housing part, is designed in black, for example, anodized black. In a preferred embodiment, a thermally conductive material, in particular a thermally conductive paste and particularly preferably a permanently elastic thermally conductive paste, is provided in the interior of the housing. This can transfer heat from the electrical components to the metallic housing part. This enables improved passive cooling of the assembly.

[0023] In a further advantageous embodiment, at least one sealing device is arranged between the first housing part and the second housing part. This sealing device can be provided, for example, as a circumferential seal, such as a silicone seal. It should be noted that an assembly position or installation situation occurs in an exposed location in the vehicle.

[0024] For example, the assembly can be screwed to the so-called shear panel, for example, to the lowest level in a vehicle facing the road. This poses a particular risk of stress on the assembly from saltwater and / or rainwater. For example, a fluid could penetrate the housing, resulting in a short circuit or damage to electronic components. The design described here preferably results in only a single sealing level facing outwards for the CPM module (Car Pad Module), and in particular, a circumferential sealing level.

[0025] Preferably, the assembly therefore has only one sealing level, through which, as mentioned above, no liquid can pass. Preferably, the housing of the assembly is completely sealed. The presence of only a single sealing level increases the process reliability of the product with regard to its production and preferably also reduces the risk of functional failure in the field or during operation. In addition, a single sealing level also leads to more cost-effective production of the CPM module. As mentioned above, the sealing device can, for example, be an applied sealing device. It would also be possible for the sealing device to be an adhesive bond, for example an adhesive bond between the two housing halves or housing parts. An application and / or an adhesive bond is therefore preferably used for sealing purposes.

[0026] According to the invention, a circumferential gap is formed between these two housing parts, within which at least one sealing means is particularly preferably arranged. This gap extends in a labyrinthine manner toward the interior of the housing, or this gap changes direction at least twice. These directions can be perpendicular to each other.

[0027] The housing preferably has a so-called drip edge at least in sections. Such a drip edge offers additional protection for the seal, particularly when the CPM module is being cleaned, for example, with a steam jet. This drip edge is preferably formed circumferentially around the housing. This drip edge is preferably an edge formed in particular on the second and / or lower housing part, which is in particular designed to project. In this way, any liquid present can be effectively drained away. This enables improved protection against splash water.

[0028] The at least one electrical component is a coil. Thus, the assembly is preferably a coil arrangement, which is used in particular for electrical charging systems and which can be supplied with electrical energy, for example, by another charging coil.

[0029] Preferably, the coil device and in particular a stranded wire of the coil device is connected to a circuit board in a vibration-resistant manner. In this case, the connection of the stranded wire to the circuit board can, for example, be connected to a corresponding design of a turned part. This turned part is preferably designed as an SMC component and a cable lug is preferably arranged on it. Such a cable lug can then be screwed to the turned part. In addition, it is also possible for a connecting means and / or a fastening device such as a screw to be additionally secured with an adhesive to prevent loss and thus avoid the risk of short circuits. The connection of a cable lug to the stranded wire or the coil can, for example, be achieved using a so-called hot crimping process.

[0030] In a preferred embodiment, the device further comprises a ferrite element or a ferrite body, for example a so-called ferrite mirror. The coil can bear against this ferrite body (in particular with an insulating material arranged therebetween), so that the ferrite body is arranged, for example, such that the coil bears against the ferrite body and the coil is provided between the plastic housing part and the ferrite element. Particularly preferably, this functional region, which contains the stranded wire and the ferrite body, can be compacted in a fluid-tight region and particularly preferably compacted with the aid of a potting material. The potting material is particularly preferably an epoxy resin.

[0031] This potting material can increase the strength of the CPM module. Force flow is thus better transmitted through one plastic housing part to a second housing part, for example the aluminum housing part. The aluminum housing part, which is preferably braced to increase flexural strength and particularly preferably braced on its underside, absorbs the most deformation energy due to its significantly higher modulus of elasticity. This also ensures the functionality of the ferrite element(s) in the event of breakage. In addition, the stranded wire or coil can also be protected. In particular, this reduces the risk of short circuits within the stranded wire. This could be caused, for example, by abrasion caused by vibration.

[0032] In addition, the ferrite body or ferrite elements of this ferrite body are protected from vibration. In a preferred embodiment, the ferrite body is provided with at least one protective element. This protective element preferably comprises and is preferably made of a plastic. This plastic material is preferably elastic in order to reduce the resulting stress and / or deformation of the ferrites when the housing is deformed by external forces, thus protecting the ferrites from breakage or chipping of small particles.

[0033] In a further advantageous embodiment, the structural unit can be screwed directly to the frame of a vehicle and in particular directly to the shear field of a vehicle. This direct screw connection has the advantage that heat can be dissipated more effectively via the thermally conductive pad, in particular the one housing part. This thermally conductive pad or the housing part serving as a thermally conductive pad enables heat dissipation to the shear field of a motor vehicle within certain limits. However, due to this direct screw connection, assemblies in the vehicle and also driving operation can also cause unwanted vibrations in the structural unit. This can also lead to damage to interfaces in the assembly. It is therefore proposed that a seal, in particular a silicone seal, be applied to the aluminum housing part. Such seals are advantageously applied at each screw point.By applying such seals at each screw location, the penetration of harmful fluids between the aluminum housing part and the thrust field can be prevented.

[0034] This seal can, for example, be a sealing ring arranged in the region of the housing part, but in particular outside the housing. Therefore, the assembly preferably has at least one sealing device and / or damping device arranged on an outer surface of the housing, which dampens vibrations acting on the assembly, particularly when mounted on a vehicle.

[0035] In a further advantageous embodiment, the two housing parts are mounted so as to be movable relative to one another in the longitudinal direction and / or the width direction, or a certain amount of play is allowed between the two housing parts in at least one plane of movement. It is thus proposed that these housing parts be mounted so as to be movable relative to one another, for example, in at least one direction and preferably in two directions.

[0036] Preferably, the ferrite components, the coil, and / or the circuit board or protective frame are integrated into the plastic part, i.e., a housing part. As mentioned, these are connected to the second housing part, such as the aluminum housing part, in a movable manner, for example, floating. Due to the greatly differing thermal conductivities of the two housing parts, the two materials experience greatly differing changes in length. For example, the thermal conductivity of an aluminum housing part is approximately 150 W / mK, while the thermal conductivity of the plastic housing part is approximately 0.7 W / mK. The aluminum housing part is preferably connected to the plastic housing part with metal screws, particularly aluminum screws. Such screws have the least impact on electrical function.

[0037] In a further advantageous embodiment, circuit boards can be made of epoxy resin, for example, and a protective frame (e.g., made of polyester resin) can be integrated and / or attached to the plastic housing part. This way, even during a temperature shock test, the circuit board is not subjected to stress. In such a temperature shock test, the entire module or assembly can be moved from a room with +105°C to a room with -40°C within five seconds.

[0038] In a further advantageous embodiment, the fastening means for attaching the assembly to the vehicle are mounted on one housing part. Holes are provided in the other housing part, in particular the aluminum housing part. These holes are preferably designed such that the fastening means have a certain amount of play within the fastening means.

[0039] As mentioned above, the structural unit preferably comprises a cooling device for cooling the at least one electrical component. One of the two housing parts, and in particular the metallic housing part, preferably serves as the (in particular passive) cooling device. A heat-conducting means, in particular a heat-conducting pad, is preferably provided. In a further advantageous embodiment, a plurality of projections are arranged on one housing part, which engage in recesses arranged on the other housing part. For example, supports can be provided inside the plastic housing part, which serve for the corresponding plastic parts of the insulation, in order to accommodate the loads occurring, in particular in the Z-direction of the structural unit, i.e. in the vertical direction during driving operation.

[0040] In general, loads on the assembly or component can also be exerted by forces introduced via the so-called shear field. Due to the material's properties, these tasks should primarily be performed by an aluminum housing component. The movable or floating connection between the two housing components is intended to reduce deformation forces, particularly on the plastic housing component, to prevent damage to the functional components integrated within it (ferrites, stranded wire, and circuit board).

[0041] In a preferred embodiment, the electrical component is attached to one of the two housing parts and in particular to the plastic housing part.

[0042] The present invention is further directed to a device for inductively charging motor vehicles, which comprises an electrical unit of the type described above. Preferably, the inductive charging unit also comprises a second coil device, which is suitable and intended to cooperate with the unit described here for the transmission of inductive energy.

[0043] The present invention is further directed to a device for inductively charging motor vehicles. This device comprises a housing and electrical components arranged within this housing, wherein these electrical components comprise at least one coil device, a ferrite body, and a component board. Furthermore, the device has at least one interface arranged at least partially outside the housing, which enables an electrically conductive connection or contacting of at least one of the electrical components. Furthermore, the ferrite body is a plate-shaped body.

[0044] Preferably, the plate-like body comprises a plurality of plate-like ferrite segments spaced apart from one another. This increases the fracture strength overall, even with thin plates. Gaps are advantageously formed between the individual ferrite segments. A material can be located in these gaps, as described in more detail below.

[0045] Preferably, the ferrite segments each have a thickness that is greater than 1 mm, preferably greater than 2 mm, preferably greater than 3 mm, and particularly preferably greater than 4 mm. Preferably, the ferrite segments each have a thickness that is less than 20 mm, preferably less than 15 mm, preferably less than 10 mm, preferably less than 8 mm, particularly preferably less than 6 mm, and particularly preferably less than 5 mm. Here, too, the housing preferably has a first housing part and a second housing part, as well as a sealing device that is present at least in sections between the two housing parts.

[0046] The present invention is further directed to a device for inductively charging motor vehicles. This device has a housing and electrical components arranged within this housing, wherein these electrical components comprise at least one coil device, a ferrite body, and a component board. In addition, the device has at least one interface arranged at least partially outside the housing, which interface enables electrically conductive contact to at least one of the electrical components. Furthermore, the ferrite body preferably has a plate-shaped configuration and / or is designed as a plate-shaped body. Furthermore, the housing has a first housing wall and a second housing wall, which lies opposite this first housing wall.

[0047] Preferably, the component board is spaced apart from both the first housing wall and the second housing wall, and a heat-conducting material is arranged between the component board and at least one of the housing walls.

[0048] The housing preferably has a first housing part and a second housing part, which are particularly preferably arranged adjacent to one another. The coil device is preferably arranged in one of the housing parts, and the component board is arranged in the other housing part. The ferrite body is preferably arranged in the same housing part in which the coil device is arranged.

[0049] In this embodiment, it is proposed that, in particular, a thermally conductive material connects the component board to at least one housing wall in a thermally conductive manner. This is preferably a metallic housing wall, for example, made of aluminum. The thermally conductive material serves, in particular, to dissipate heat from the component board or electronics board.

[0050] Said circuit board can particularly preferably comprise power electronics. In addition, the circuit board can also comprise circuits and the like. Preferably, the device also comprises a fastening device for attachment to a motor vehicle.

[0051] In a further advantageous embodiment, the above-mentioned ferrite segments are at least partially movable relative to one another. In this way, greater fracture resistance of the entire ferrite body can be achieved. This is advantageous in connection with a motor vehicle in which the device according to the invention is also subject to strong vibrations, for example, vibrations that occur during driving, but also increased vibrations that can occur, for example, due to uneven roads and the like.

[0052] Preferably, the individual ferrite segments are at least partially connected to one another in an articulated manner. This means that a ferrite segment can preferably pivot relative to another ferrite segment by a predetermined angle and can preferably pivot relative to this adjacent ferrite segment with respect to a pivot axis defined by a gap between the segments. This pivotability is preferably enabled by a material arranged between the respective ferrite segments. This material is preferably elastic.

[0053] Therefore, the ferrite body is designed to withstand such shocks.

[0054] In a further advantageous embodiment, a plastic material is arranged at least partially and / or in sections between the ferrite segments. This can advantageously be silicone, for example, silicone rings placed around the individual ferrite segments. The ferrite segments can have grooves on their side sections into which a ferrite ring can be inserted.

[0055] In a further advantageous embodiment, a plastic ring is arranged around at least one ferrite segment's entire circumference. Advantageously, this plane of the ring corresponds to the plane of the segment.

[0056] In a further advantageous embodiment, a plastic material is arranged around the ferrite body. This can, in particular, also be a material that serves as a seal.

[0057] In an advantageous embodiment, the individual ferrite segments are plate-like. The ferrite segments are preferably each of the same design. Particularly preferably, they are essentially square plates, which are particularly preferably arranged in an array. Thus, a plurality of plates can be arranged next to one another in a first direction and preferably also in a second direction perpendicular to the first direction.

[0058] In a further advantageous embodiment, this creates an overall element with limited flexibility, which can also compensate for shocks and vibrations without individual or multiple ferrite elements breaking or being damaged in any other way.

[0059] In a further advantageous embodiment, a plane formed by the coil device and a plane formed by the ferrite body are parallel to each other. The ferrite body preferably serves to shield and / or focus a field.

[0060] In a further advantageous embodiment, the coil device is arranged on the ferrite body and, particularly preferably, slightly spaced therefrom. It is also possible for the coil device to be arranged on the ferrite body with a fastening means, for example, cast therein. This fastening material or fastening means is preferably designed to be insulating.

[0061] The fastening means and / or fastening material is preferably a plastic material. This material is preferably elastic in order to protect the resulting stress and / or deformation of the ferrite elements from breakage or chipping of small particles in the event of deformation of the housing due to external forces.

[0062] Preferably, a single component and in particular the said housing part and in particular a single component made of plastic serves as a receptacle for the coil device and the ferrite elements (possibly together with their protective elements).

[0063] This plastic component preferably creates a defined position and / or receptacle for the coil device and / or the ferrite body (optionally with its protective elements) through a corresponding structural design. This component and / or optionally another component preferably transmits the forces acting in the Z direction to another component, and in particular to the aforementioned additional housing part (which is preferably made of metal), through a corresponding structural design.

[0064] Preferably, the coil device and in particular also the ferrite body are mounted with at least one and preferably several bearing points relative to the plastic housing part. This mounting is particularly preferably designed such that the coil device and / or the ferrite body cannot move in the aforementioned Z direction.

[0065] The device preferably comprises a support that serves to hold both the coil device and the ferrite body. This support is preferably made of an electrically insulating material, in particular an electrically insulating plastic. This support can also be arranged between the coil device and the ferrite body to enable electrical insulation between these components.

[0066] In a further advantageous embodiment, the coil devices of the ferrite bodies are therefore at least partially encapsulated together. This also increases the stability of the arrangement. Particularly preferably, the coil devices of the ferrite bodies are encapsulated together with an epoxy resin.

[0067] In a further advantageous embodiment, at least one and preferably a plurality of bearing points and / or bearing elements are provided between the coil device and the ferrite body. The coil device is thus preferably mounted relative to the ferrite body and, in particular, mounted in a direction perpendicular to a plane of the coil device.

[0068] In a further advantageous embodiment, the bearing elements can each be point bearings.

[0069] Preferably, the coil devices and the solid body are arranged in a first region of the housing, and the component board is arranged in a second region spaced therefrom. Thus, the housing can form a first chamber for accommodating the ferrite body and the coil device, as well as a second chamber for accommodating the electronics board or electronic unit.

[0070] In a further preferred embodiment, the coil device and / or the ferrite body is attached and / or held laterally to the housing.

[0071] In a further advantageous embodiment, the thermally conductive material is a thermally conductive paste, preferably a flexible paste. This flexible paste can also prevent or dampen impacts on the circuit board. Thus, the paste can act both as a thermally conductive medium and for impact and shock absorption.

[0072] In a further advantageous embodiment, this thermally conductive paste is arranged on multiple sides of the electronic circuit board, and in particular on at least two opposite sides. In particular, as mentioned, the thermally conductive paste is arranged between the electronic circuit board and the housing wall, and particularly preferably also on the respective opposite wall of the electronic circuit board. This allows for particularly efficient heat dissipation from the electronic circuit board.

[0073] In a further advantageous embodiment, the paste is a substance selected from a group of substances containing silicone. Furthermore, this paste can also contain thermoplastics. In addition, this substance can contain heat-conducting substances, in particular heat-conducting particles. These can be, for example, metallic particles, such as copper, silver, or aluminum particles.

[0074] In a further advantageous embodiment, the coil devices and the ferrite body are arranged within the plastic housing part. In this case, it is possible for the coil device, in particular, to be located entirely within this housing part, i.e., in particular, not to protrude beyond this housing part in a direction perpendicular to its plane. Preferably, the electronic circuit board is arranged in the other housing part or in the region of the second housing part. However, the necessary clearance and creepage distances are preferably maintained.

[0075] The procedure described here makes it possible, on the one hand, to achieve a low overall height of the device, i.e., a low overall height when viewed in a vertical or Z-direction. To achieve this requirement, a part of the coil device, and in particular a strand of the coil device, is particularly preferably guided through the ferrite body and / or the ferrite field in a protected and / or insulated manner.

[0076] In a further preferred embodiment, the interior of the housing is divided into regions, one containing the stranded wire or coil device and the ferrite body, and the other containing the circuit board. Particularly preferably, the device comprises a protective frame that at least partially surrounds the electronic circuit board. A connection panel is preferably also provided on this protective frame and / or the electronic circuit board. This connection panel allows, in particular, electrical contacting of the circuit board.

[0077] According to the invention, the housing has a wall arranged inside the housing and at least partially separating a first region of the housing from a second part of the housing. The first part of the housing is a region of the housing formed by the first housing part, and the second part of the housing is a region of the housing formed by the second housing part. These two regions of the housing can be arranged one above the other in the z-direction, but they can also be arranged next to each other in a horizontal direction.

[0078] Preferably, the above-mentioned electronic circuit board is arranged in said first region of the housing and the coil device and the ferrite body are arranged in the second housing part.

[0079] Preferably, said wall is continuous within the housing and extends in particular in the longitudinal direction of the housing and the width direction perpendicular to the longitudinal direction. This wall preferably seals the two regions of the housing from each other in a fluid-tight manner, particularly in a liquid-tight manner.

[0080] In one embodiment, this wall is designed as a cover, which in particular covers the ferrite body or its ferrite elements. Preferably, this wall or cover also serves as electrical insulation between the ferrite body and the metal housing part. Thus, this wall can also extend into a transition section between the two housing parts.

[0081] In a preferred embodiment, the wall is made of a plastic. This wall can also serve to support and / or hold the ferrite body. Thus, this wall can have a structural design that is suitable and intended to enable a defined reception of the ferrite body.

[0082] Furthermore, this wall can be designed in such a way that, through appropriate structural design, it transmits forces acting in the z-direction to the housing part made of metal. Preferably, said wall is made of a plastic.

[0083] However, it should be noted that the said wall can also be used independently of the above-mentioned embodiments, i.e. in particular independently of the embodiment according to which the housing parts are made of different materials.

[0084] In a further preferred embodiment, however, the wall has means and / or at least one opening for passing through at least one electrical line.

[0085] In a further preferred embodiment, the wall rests at least partially on a portion of the second housing part. Preferably, the wall rests on the portion of the second housing part at individual defined bearing points or completely circumferentially. Preferably, the wall is formed in a sealing manner with the second housing part and particularly preferably is glued. Preferably, the wall, together with the second housing part, forms a receiving space for accommodating the coil device and the ferrite body, wherein this receiving space is preferably fluid-tight.

[0086] Preferably, such an applied seal or adhesive is applied to the wall or the cover and / or to the second housing part (which, as mentioned above, consists of a plastic).

[0087] In a further preferred embodiment, a potting material is provided at least partially in the space formed by the wall within the second housing part. This potting material can be provided, in particular, in the predetermined spaces between the coil device, the ferrite body, and the second housing part. In other words, by appropriately designing the second housing part (made of plastic), the coil device and the ferrite body, a support for the ferrite body, and the wall, a potting material can be introduced into the provided spaces (in particular, in this fluid-tight space for all components).

[0088] By filling the gaps with a potting material, a so-called compaction of all components located in the fluid-tight space can be achieved. This compaction preferably increases the inherent rigidity and / or strength of the entire housing. For this purpose, the potting material can be epoxy resin, for example.

[0089] In a further advantageous embodiment, bearing points can be provided between a carrier and in particular a plastic carrier of the ferrite body, which protect the ferrite body from damage by forces occurring in the z-direction.

[0090] The aforementioned protective frame for the circuit board is particularly suitable for mounting the circuit board. This ensures that the electronic circuit board maintains a defined distance from the housing part, for example, the aluminum housing part. The paste, as mentioned above, also serves to dissipate heat.

[0091] This also protects the electronic components on the circuit board, for example, during assembly work. In particular, this method can be used to secure the cable lugs within a connector panel.

[0092] In addition, this protective frame's design also allows for the protection of the circuit board and the electronic components on it, particularly against vibration.

[0093] In a preferred embodiment, the permanently elastic and / or thermally conductive paste is also used on both sides of the circuit board. This paste thus serves both the function of heat dissipation, i.e., vibration dampening, and the function of heat spreading.

[0094] In a further advantageous embodiment, the electronic circuit board and / or the coil device and / or the ferrite body are arranged within a frame element. This frame element can, in turn, be fastened in the housing part.

[0095] The present invention further relates to an inductive charging arrangement for motor vehicles with at least one device of the type described above.

[0096] Further advantages and embodiments can be seen from the attached drawings:

[0097] Showing: Fig. 1A schematic representation of a device according to the invention; Fig. 2A perspective representation of a device according to the invention; Fig. 3The representation of the device from Figure 2 in a partially opened state; Fig. 4 a detailed view of the device from Fig. 3; Fig. 5 is a representation of the device to illustrate the installation in a motor vehicle; Fig. 6 is a detailed representation of a ferrite body for a device according to the invention; Fig. 7 is a representation of the device according to the invention with a connection; Fig. 8 is a sectional representation to illustrate the connection between the housing parts; Fig. 9 is a sectional representation to illustrate the arrangement of the fastening device; Fig. 10 is a detailed representation to illustrate the connection of the device; Fig. 11 is a partial sectional representation of the device according to the invention; Fig. 12 is a representation of the second housing part; Fig. 13 is a further sectional representation of the device according to the invention; and Fig. 14 is a further sectional representation of the device according to the invention.

[0098] Figure 1shows a schematic representation of the electrical assembly according to the invention. This assembly 1 has a housing 2, wherein this housing 2 in turn has a first housing part 22 and a second housing part 24. The housing part 22 is made of a metal and the housing part 24 of a plastic. The reference numeral 50 designates a wall which separates the two housing parts from one another and, in particular, separates them from one another in a gas-tight and / or liquid-tight manner. This forms two chambers K1 and K2 inside the housing. However, there are electrical connections (not shown) between these two housing parts and the electronic elements within the housing 2.

[0099] Reference numeral 18 designates an electronic circuit board arranged in the first housing part. Reference numeral 30 designates a temperature-conducting and flexible element that establishes a connection between the electronic circuit board 18 and the wall 26 of the housing part 22. Reference numeral 4 designates a connection device for electrically connecting the device.

[0100] Reference numeral 28 denotes a second wall of the housing, which is opposite wall 26, with the electrical components described here being arranged between these walls 26 and 28. Reference numeral 10 denotes a coil device, which is arranged within the housing and in particular within the second housing part 24. Reference numeral 16 denotes a ferrite body, described in more detail below, which is also arranged within the second housing part and adjacent to the coil device 10.

[0101] It is possible for the coil device 10 and the ferrite body 16 to be cast together in a material 32. Reference numeral 33 schematically designates a holding device for holding the coil device 10 and the ferrite body. Reference numeral Z designates the Z-direction, which is generally a vertical direction.

[0102] Reference numeral 6 denotes a sealing device which is suitable and intended to seal the two housing parts 22 and 24 with respect to one another. As described in more detail below, this can also be a circumferential seal. Preferably, the plate or wall 50 is also arranged between the two housing parts 22 and 24. Reference numeral L denotes a longitudinal direction of the housing 2. A width direction B is perpendicular to the plane of the figure (cf. Fig. 3 ).

[0103] Figure 2shows a view of a device 1 according to the invention. It can be seen here that the second housing part 24 has rounded corners 24b and also rounded edges 24a. This improves wind resistance. Reference numeral 12 denotes fastening means for attaching the device 1 to a vehicle or to a corresponding vehicle support. Also visible again is the interface 4, via which the device 1 can be electrically connected to the vehicle.

[0104] Figure 3 shows the device Figure 2 in a partially opened state. The partition wall 50 can be seen again, which fluid-tightly separates the interior space formed by the first housing part 22 and the interior space formed by the second housing part 24.

[0105] Reference numeral 36 denotes a component of an electronic device. It can be seen that the device has a plurality of fastening means 12, which are arranged here on the second housing part 22 and can, for example, be screwed and / or pushed into it from below. Reference numeral 6 denotes a circumferential sealing device which, in an assembled state, seals the two housing parts 22 and 24 from one another and thus, in particular, also prevents liquids from entering the interior of the housing. Reference numeral 38 denotes supports which interact with projections 34, which are arranged here on the first housing part 22. Reference numeral 52 denotes sealing devices, such as sealing rings, which serve to seal the openings through which the fastening devices 12 are guided.

[0106] Figure 4shows an enlarged view of a section of the housing. The two fastening devices 12 and the sealing devices 52 are again visible. Also visible is the gap S between the first housing part 22 and the second housing part 24. This gap is also sealed, as mentioned above.

[0107] Figure 5 illustrates the installation of the device according to the invention on a motor vehicle or a support 60 of the motor vehicle. It can be seen that the housing part 22 rests at least partially against this support 60. The individual seals 52 are also visible, as are the screws 12, which are subsequently passed through these seals and can be screwed to the vehicle support or a fastening device.

[0108] Figure 6shows the ferrite body 16, which is arranged entirely within the second housing part 22 (not shown here). This ferrite body 16 has a plurality of ferrite segments 16a, 16b, 16c, which are arranged in a square here. Sealing devices are provided between these individual ferrite segments 16a, 16b, 16c, wherein these sealing devices can, in particular, surround the individual ferrite segments circumferentially. It is possible for such a seal to be applied or drawn around each individual ferrite segment 16a, 16b, 16c. In this way, the individual ferrite segments 16a, 16b, 16c are movable relative to one another to a certain extent and are thus mounted in a floating manner.

[0109] Bearing elements 62 can also be seen, which are also arranged in the lower housing part (not shown). These elements allow, in particular, a floating bearing in the Z direction, i.e., in the direction pointing toward the road, of the two housing parts relative to each other. These bearing elements interact, in particular, with the projections 34 and can protrude into them in sections.

[0110] This is explained in more detail below. The fastening devices 12 are also shown again. It can be seen that, in an assembled state, the fastening devices 12 therefore protrude further upward than the bearing elements 62. The bearing elements 62 are also arranged lower within the second housing part than the fastening devices 12.

[0111] Figure 7shows another view of the device according to the invention, again showing the two housing parts 22 and 24. The circumferential gap or separation point between the housing parts is also visible. The fastening device 12 and the retaining shoe for the interface 4 are also visible.

[0112] Figure 8shows a sectional view of the device according to the invention. Here, the housing part 22 and also the housing part 24 are shown again. It can be seen that these two housing parts are connected to one another in a labyrinth-like manner. It can be seen more precisely that the gap S does not lead directly into the interior of the housing, but rather in the manner of a labyrinth, first upwards and then horizontally to the left. In this way, a reliable liquid seal can be achieved. Furthermore, two sealing devices 51, 53 can be seen, which seal the spaces between the two housing parts 22 and 24. In this way, the housing is secured with two sealing devices arranged one behind the other. In this way, not only can a seal be maintained against normal splash water, but also a seal, for example, in the event of an underbody wash for the vehicle.The reference number 54 shows a recess into which a tool can be inserted.

[0113] Reference numeral 35 again designates the bearing device in its entirety. It can be seen that this bearing device 35 comprises the bearing element 62 with a screw recess 55, for example, for inserting a tool. Reference numeral 56 designates a sealing element, such as a flexible disk, which generates a certain tension or damping of the bearing, particularly in the Z direction. The bearing element 62 rests entirely on the damping disk 56.

[0114] Reference numeral 58 designates a recess or bore in the housing part 24 into which the bearing element 62 can be screwed. This recess is in turn arranged within the projection 34. In this way, the projection 34 is also supported relative to the second housing part 24. This damping disc thus enables a floating support of the two housing parts 22, 24 relative to one another. This damping disc preferably enables both play or a floating support in the Z direction and in directions perpendicular thereto. It can be seen that an outer circumference of the bearing elements 62 is smaller than an inner circumference of the projections 34, so that the bearing elements 62 can also be moved relative to the projections 34 in a plane which is perpendicular to the Z direction. In this way, a floating support of the housing parts relative to one another is also achieved in this plane.

[0115] Figure 9shows a representation of the fastening of the two housing parts to another element, for example, a support 60 of a motor vehicle. The fastening means 12 is provided, which can be inserted into a recess 76 of the second housing part 24 and screwed to the first housing part. For this purpose, the fastening means 12 has a recess 74 into which a tool can be inserted. The reference numeral 63 denotes a damping means or a sealing device, which is arranged between the two housing parts 22 and 24. This damping means can also be a component of the sealing device designated above with 6.

[0116] Figure 10shows an illustration of the arrangement of the interface 4. This interface 4 has a coupling device 42, which can interact with a further coupling device (not shown). The reference numeral 44 denotes a channel, which here is bent by 90° starting from the holding device 41 in order to thus have a horizontal orientation of the coupling device 42. In addition, the two housing parts 22 and 24 are again shown, as well as the fastening elements 12. It is possible for the interface and / or the holding device to be rotatable relative to the first housing part 22, for example, rotatable by an angle of 90° with respect to the Z direction.

[0117] Figure 11shows a partial sectional view of a device according to the invention. Here, the transition between the housing parts 22 and 24 can be seen again on the left side, and the gap between the two housing parts is designed in a labyrinthine manner to prevent liquids from penetrating the interior of the housing. Next to it, one can again see the bearing element 62, which is screwed into the first housing part 22, as well as the associated sealing element 56, which enables the spring-loaded mounting of the two bearing parts 22, 24 relative to one another in the direction Z. Arranged within the second housing part 24 are both the coil device 10 and the ferrite body 16. The coil device 10 is arranged here on a carrier 11, with the individual windings of the coil lying in corresponding recesses in the carrier 11. The carrier 11 can be made of a polyester resin.Reference numeral 77 denotes a spacer which spacers the coil device and / or the carrier from the housing part.

[0118] Reference numeral 25 denotes a sealing means arranged on the second housing part, which also serves, in particular, to form the labyrinth-shaped gap. Reference numeral 65 denotes a sealing means for sealing the housing parts from one another. Reference numeral 67 denotes a further sealing means for sealing the wall 50 from the lower housing part 24.

[0119] The ferrite body 16 here again has gaps or plastic parts 14 between the individual ferrite segments. A plurality of bearing elements 17 are provided between the coil device 10 and the ferrite body 16, which support the coil device 10 and the ferrite body 16 relative to one another, particularly in the Z direction. In addition, the coil device 10 and the ferrite body 16 can be cast in a plastic material relative to one another.

[0120] Reference numeral 50, in turn, designates the cover plate, which covers the components arranged in the second housing part 24. This cover plate can also be sealed from the housing part 24 by means of a sealing device 51, which can also be designed, for example, as a circumferential ring. In this way, the region of the housing in which the coil unit 10 and the ferrite body 16 are arranged is separated from the upper region of the housing, in which, in particular, the electronic circuit board 18 is also arranged. Damping elements can, in turn, be provided between the ferrite body 16 and the cover wall 50, which in turn protect, in particular, the ferrite body 16 in the event of vibrations or impacts in the Z direction.

[0121] Here again it is possible that the ferrite body 16 is mounted in a floating manner.

[0122] Figure 12shows a further illustration of the device according to the invention. Here, too, the coil device 10 and the ferrite body 16 can be seen. In addition, the cover wall 50 is shown, which serves to seal the housing part and the electronic components arranged therein. Reference numeral 15 denotes a step in the second housing part, which is supported relative to the coil device 10. In this way, the coil device 10 is held within the housing part 24.

[0123] Figure 13shows a further sectional view of the device according to the invention. Reference numeral 22 again refers to the first housing part, and reference numeral 24 to the second housing part. Reference numeral 18 denotes the electronic circuit board, which is held in the first housing part 22. An elastic thermally conductive paste is arranged in the region 30, which conducts heat generated on the electronic circuit board to the first housing part 22. It can be seen that the wall 50 here again separates the space or chamber in which the coil device and the ferrite body are arranged from the space or chamber in which the electronic circuit board 18 is arranged, with these spaces also being laterally adjacent to one another.

[0124] Reference numeral 110 denotes a protective frame or holding frame, which serves in particular to hold the electrical components. The coil device can also be arranged on this protective frame 110. Reference numeral 19 denotes strands of the coil device. Reference numeral 107 denotes a component which also serves in particular to attach a cable lug 109. This attachment is effected by means of a screw 105. The protective frame can also be supported against the bottom surface of the second housing part.

[0125] Figure 14shows another sectional view of the device according to the invention, but here without the first housing part 22. The screw means which serves to fasten the cable lug can again be seen. A projection or a positioning element 111 which also serves in particular to position the electronics board 18 is arranged on the protective frame 110. It is also pointed out that features which can be advantageous in themselves have been described in the individual figures. The person skilled in the art will immediately recognize that a specific feature described in a figure can also be advantageous without the adoption of further features from this figure. Furthermore, the person skilled in the art will recognize that advantages can also arise from a combination of several features shown in individual or different figures. List of reference symbols

[0126] 1Device 2Housing 4Connection device / interface 6Sealing device 10Coil device 11Carrier 12Fasteners 14Plastic parts 15Stepping of the second housing part 16Ferrite body 16a, 16b, 16cFerrite segments 17Bearing elements 18Electronic circuit board 19Leads 22First housing part 24Second housing part 24aRounded edges 24bRounded corners 25Sealing means 26Wall 30Temperature-conducting and flexible element 32Material 34Protrusions 35Bearing device 36Component of an electronic device 38Support 41Holding device 42Coupling device / connecting device 44Channel 50Partition wall / wall / cover plate / cover wall 51, 53Sealing device 54Recess for tool 52Sealing devices 55Screw recess 56Sealing element / damping disc 58Recess / bore 60Carrier of the motor vehicle 62Support elements / bearing elements 65,67Sealant 72Fasteners 74Recess of the fastening device 76Recess 77Spacer 105Screws 107Component 109Cable lug 110Protective frame 111Positioning element , SSlit ZZ-direction

Claims

1. Electrical construction unit (1) for motor vehicles, having a housing (2) within which at least one electrical component (10) is arranged, having an interface (4) which enables electrically conductive contacting of this component (10), wherein the housing (2) having a first housing part (22) and a second housing part (24) which are fastened to one another by at least one fastening means (12) and wherein the two housing parts each extend at least along a longitudinal direction (L) and a width direction (B) perpendicular to this longitudinal direction (L), wherein the first housing part (22) and the second housing part (24) are made of different materials, wherein the electrical construction unit contains at least one coil which is suitable and intended for the transmission of electrical energy by inductive means, characterized in that a circumferential gap (S) is formed between the two housing parts (22, 24), within which gap at least one sealing means is arranged, wherein this gap extends in the direction of the interior of the housing in a labyrinth-like manner and changes its direction at least twice and the housing has a wall (50), which is arranged in the interior of the housing and at least partially separates a first region of the housing from a second part of the housing and separates the two regions of the housing from one another in a fluid-tight manner, wherein the first part of the housing being a region (K1) of the housing formed by the first housing part and the second part of the housing being a region (K2) of the housing formed by the second housing part.

2. Electrical construction unit (1) according to claim 1, characterized in that a housing part (22, 24) is made of a plastic material.

3. Electrical construction unit (1) according to at least one of the preceding claims, characterized in that a housing part (24, 22) is made of a metal.

4. Electrical construction unit (1) according to at least one of the preceding claims, characterized in that a fastening means (12) is arranged on at least one housing part (22, 24) in order to fasten the electrical construction unit (1) to the motor vehicle.

5. Electrical construction unit (1) according to at least one of the preceding claims, characterized in that the two housing parts (22, 24) are mounted so as to be movable relative to one another in the longitudinal direction (L) and / or the width direction (B).

6. Electrical construction unit (1) according to at least one of the preceding claims, characterized in that the construction unit (1) has a cooling device for cooling the at least one electrical component (10).

7. Electrical construction unit (1) according to at least one of the preceding claims, characterized in that a plurality of projections (72) are arranged on one housing part (24), which engage in recesses (34) arranged on the other housing part.

8. Electrical construction unit (1) according to at least one of the preceding claims, characterized in that the electrical component (10) is attached to only one of the two housing parts (22, 24).