Vehicle module cpm of an inductive charging system for a vehicle

Abstract

The invention relates to a vehicle module CPM for converting electromagnetic energy of an electromagnetic field, which is generated by a ground module GPM of an inductive vehicle charging system, into electric energy of an electric current and for charging an electric storage device and / or for operating an electrical load in the vehicle, said vehicle module CPM comprising: a main coil assembly (101) with a main coil for converting the electromagnetic field into an electric alternating current AC, and an electronic assembly (102) comprising power electronics (105) for converting the electric alternating current AC into a direct current DC. The vehicle module CPM is characterized in that one or more heat tubes (103) are provided for transferring / distributing heat generated locally in the main coil assembly (101) and / or in the electronic assembly (102) during the energy conversion operation, and the heat tubes (103) transfer the locally generated heat in particular from the main coil assembly (101) to the electronic assembly (102) and vice versa. The electronic assembly (102) has a channel (104) through which a refrigerant fluid can flow and which can be connected to an external heat exchanger. The channel (104) is designed to transfer heat from the electronic assembly (102) to the refrigerant fluid.

Description

[0001] Vehicle module CPM of an inductive charging system for a vehicle

[0002] The invention relates to a vehicle module CPM of an inductive charging system for a vehicle.

[0003] As is known, inductive charging systems for vehicles typically comprise a ground module (GPM) that is stationary on the ground and connected to a power grid, and a vehicle module (CPM) that is typically arranged on the underside of a vehicle. Typically, in such inductive charging systems, energy is inductively transferred by means of a main coil of the ground module (GPM) to a main coil of the vehicle module (CPM) arranged in the vehicle for charging an electrical storage unit / battery and / or for supplying an electrical load. The ground module (GPM) and the vehicle module (CPM) can also be configured for bidirectional energy transfer, i.e., from GPM to CPM and from CPM to GPM.

[0004] Both the GPM and the CPM typically comprise an electronic assembly and a main coil assembly with a main coil. To enable optimal electromagnetic coupling of the two main coils for energy transfer, the main coil of the GPM and the main coil of the CPM must be optimally positioned relative to each other.

[0005] During operation, i.e., during energy transfer from main coil to main coil, heat is generated in the GPM and CPM primarily in two areas: (a) in the respective electronic assembly, where a large amount of heat is generated in a relatively concentrated manner at specific locations with high local heat density, and (b) in the respective main coil assembly (main coil and ferrite), where less and relatively well-distributed heat is generated relative to the electronic assembly. The electronic assembly typically includes power electronics.

[0006] The object of the invention is to improve heat dissipation from a vehicle module (CPM) of an inductive vehicle charging system. The invention is based on the features of the independent claims. Advantageous developments and refinements are the subject of the dependent claims. Further features, possible applications, and advantages of the invention will become apparent from the following description and the explanation of exemplary embodiments of the invention, which are illustrated in the figures.

[0007] A first aspect of the invention relates to a vehicle module CPM for converting electromagnetic energy of an electromagnetic field generated by a floor module GPM of an inductive vehicle charging system into electrical energy of an electric current, and for charging an electrical storage device and / or for operating an electrical load in the vehicle, wherein the vehicle module CPM comprises: a main coil assembly with a main coil for converting the electromagnetic field into an alternating electrical current AC, and an electronic assembly with power electronics for converting the alternating electrical current AC into direct current DC.

[0008] The proposed vehicle module CPM is characterized in that one or more heat pipes are provided for transferring / distributing heat generated locally in the main coil assembly and / or in the electronic assembly during energy conversion operation, wherein the heat pipes transfer the locally generated heat from the main coil assembly to the electronic assembly and vice versa, and the electronic assembly has a channel through which a coolant fluid can flow, which can be connected to an external heat exchanger, wherein the channel is configured and designed to transfer heat from the electronic assembly to the coolant fluid.

[0009] Heat generated locally in the vehicle module CPM during energy conversion operation in the main coil assembly and in the electronic assembly is transferred between these assemblies by means of the heat pipes, so that heat is distributed essentially evenly between the two assemblies. Typically, the amount of heat generated locally in the electronic assembly is greater than in the main coil assembly. Heat is also dissipated from the area of ​​the electronic assembly through the channel through which a coolant fluid flows and which is in heat-conducting contact with the electronic assembly, which acts as a heat sink. Overall, therefore, heat generated locally in the vehicle module by means of the heat pipes is essentially evenly distributed within the vehicle module or its housing, and at the same time heat is dissipated from the electronic assembly by means of the channel through which a coolant fluid flows.Both together enable, on the one hand, improved cooling of the vehicle module CPM and, on the other hand, higher electrical power conversion in the vehicle module CPM.

[0010] The term "heat pipe" refers to a heat exchanger that utilizes the evaporation enthalpy of a medium to achieve a high heat flux density. This allows large amounts of heat to be transferred over a small cross-sectional area. A fundamental distinction is made between two types of heat pipe: the so-called "heat pipe" and the so-called "two-phase thermosiphon." The basic operating principle is the same for both designs; the difference lies in the return transport of the gaseous working medium to the evaporator, i.e., to the point where heat is added. In both designs, the return transport occurs passively and therefore without auxiliary means such as a circulation pump.

[0011] The thermal resistance of a heat pipe is significantly lower at operating temperature than that of metals. The behavior of heat pipes is therefore very similar to an isothermal change of state. A nearly constant temperature prevails along the length of the heat pipe. This allows for significantly lighter designs than conventional heat exchangers under the same operating conditions, while maintaining the same transfer capacity. By carefully selecting the heat pipe's working medium, operating temperatures from a few Kelvin to approximately 3,000 Kelvin can be achieved.

[0012] The energy transport capacity of a heat pipe depends largely on the specific enthalpy of vaporization (in kJ / mol or kJ / kg) of the working medium, not on the thermal conductivity of the vessel wall or the working medium. For efficiency reasons, a heat pipe is usually operated at just above the boiling point of the working medium at the warm end and just below the boiling point of the working medium at the cold end. It is advantageous to arrange the heat pipes at a higher density (with closer spacing between directly adjacent heat-conducting elements) in areas of the main coil assembly and / or the electronic assembly that experience high local heat generation during energy conversion operation than in areas with low local heat generation.

[0013] Advantageously, the plurality of heat pipes, each with a respective pipe length L, is / are arranged relative to one another such that directly adjacent heat pipes are spaced apart by a distance D in the range: 3 < L / D < 10. This provides an optimum for the distance D between heat pipes, so that a sufficient number of heat pipes is available for a largely uniform temperature distribution within the CPM.

[0014] Advantageously, at least some of the plurality of heat pipes are arranged in two or more parallel planes in the vehicle module CPM. It is assumed that the heat pipes are designed such that their longitudinal extension runs in one plane. They can be straight or curved. Advantageously, at least some of the plurality of heat pipes are arranged in at least two non-parallel planes in the vehicle module CPM. Advantageously, at least some of the plurality of heat pipes are arranged in two or more non-parallel planes in the vehicle module CPM.

[0015] Advantageously, at least some of the plurality of heat pipes are arranged in two or more mutually parallel planes in the vehicle module CPM.

[0016] Advantageously, at least some of the plurality of heat pipes are arranged at least in two non-parallel planes in the vehicle module CPM.

[0017] Advantageously, at least one heat pipe, or in particular all heat pipes, are arranged in a housing material of a housing of the vehicle module CPM and / or directly on the housing of the CPM and / or at least in heat-conducting contact with the housing. The main coil of the CPM advantageously comprises at least one coil wire arranged in a predetermined geometry as a coil wire arrangement. In particular, the main coil of the CPM is designed as a flat coil.

[0018] Advantageously, the material adjacent to the main coil is a ferrimagnetic or a ferromagnetic material.

[0019] Advantageously, at least one section of the at least one heat pipe is arranged substantially congruently above and / or below at least one section of the coil wire. Thus, heat generated in the coil wire can be transferred directly to the heat pipe and distributed throughout the CPM by means of the heat pipe.

[0020] If the coil wire arrangement has an increased coil wire density in at least one region of the CPM, sections of several of the heat pipes are advantageously arranged in this region at a higher density than in other regions of the coil wire arrangement with a low coil wire density.

[0021] Advantageously, the main coil consists of at least one coil wire, the main coil has at least one region with an increased coil wire density, wherein in this region sections of several of the heat pipes are arranged in a higher density than in other regions of the main coil.

[0022] Advantageously, a section of the one heat pipe or respective sections of the plurality of heat pipes are arranged above and / or below the coil wire arrangement in the intermediate region between individual coil wire windings.

[0023] Advantageously, the at least one coil wire of the coil wire arrangement is arranged / wound in only one coil wire plane and the at least one heat pipe or the plurality of heat pipes are arranged parallel to the coil wire plane.

[0024] Advantageously, at least one of the heat pipes is arranged along the coil wire wound around the coil wire.

[0025] Advantageously, the at least one coil wire is wound around at least a portion of the at least one heat pipe. In an advantageous embodiment, the at least one coil wire is designed as a heat pipe.

[0026] Advantageously, the main coil of the main coil assembly of the CPM is embedded in a first thermally conductive material. Advantageously, a power electronics component of an electronic assembly of the CPM is embedded in a second thermally conductive material that is thermally conductively connected to the first thermally conductive material.

[0027] Advantageously, the housing of the CPM is made of a material with a thermal conductivity A > 100 W / (m *K), in particular > 150 W / (m *K).

[0028] Advantageously, the housing of the CPM has a structured outer surface which is in thermally conductive contact with one or more of the heat pipes.

[0029] Advantageously, the main coil assembly and the electronic assembly are spatially separated from one another within the vehicle module CPM, with a wall arranged between the two assemblies, which is designed as a heat-conducting element. Advantageously, the heat-conducting element is made of a material with a thermal conductivity of A > 10 W / (m *K) or A > 100 W / (m *K) or A > 150 W / (m *K) or A > 200 W / (m *K) or A > 300 W / (m *K). Advantageously, at least one heat pipe is connected to the heat-conducting element in a thermally conductive manner.

[0030] Advantageously, the main coil assembly comprises a main coil, wherein the main coil is embedded in a first thermally conductive material.

[0031] Advantageously, the electronic assembly comprises power electronics, wherein the power electronics are embedded in a second thermally conductive material which is thermally conductively connected to the first thermally conductive material.

[0032] Advantageously, the housing of the vehicle module CPM has a structured outer surface that is in thermally conductive contact with at least one or more of the heat pipes. When the vehicle module is installed on the vehicle, the outer surface advantageously faces downward and is advantageously freely exposed to ambient air. A second aspect of the invention relates to an inductive charging system for a vehicle for charging an electrical storage device of the vehicle, comprising at least one floor module GPM and one vehicle module CPM, wherein energy is transferred at least from the floor module GPM to the vehicle module CPM, and wherein the vehicle module CPM is configured as described above.

[0033] A third aspect of the invention relates to a vehicle with a vehicle module CPM as described above.

[0034] Further advantages, features, and details will become apparent from the following description, which – where appropriate with reference to the drawings – describes at least one embodiment in detail. Identical, similar, and / or functionally equivalent parts are provided with the same reference numerals.

[0035] It shows:

[0036] Fig. 1 is a schematic representation of a vehicle module CPM according to the invention

[0037] Fig. 1 shows a schematic representation of a vehicle module CPM according to the invention for converting electromagnetic energy from an electromagnetic field generated by a floor module GPM of an inductive vehicle charging system into electrical energy of an electric current, and for charging an electrical storage device and / or operating an electrical load in the vehicle. The vehicle module CPM comprises a main coil assembly 101 with a main coil 106 for converting the electromagnetic field into an alternating electrical current AC, and an electronic assembly 102 with power electronics 105 for converting the alternating electrical current AC into direct current DC.

[0038] The vehicle module CPM comprises five heat pipes 103 arranged above the main coil for transferring / distributing heat generated locally in the main coil assembly 101 and / or in the electronic assembly 102 during energy conversion operation. The heat pipes 103 transfer the locally generated heat from the main coil assembly 101 to the electronic assembly 102 and vice versa. The electronic assembly 102 has a channel 104 through which a coolant fluid can flow, which can be connected to an external heat exchanger. The channel 104 is configured and designed to essentially transfer heat from the electronic assembly 102 to the coolant fluid and thus dissipate it.

[0039] The refrigerant fluid flows through the channel 104, as indicated by the associated arrows.

[0040] Although the invention has been illustrated and explained in detail by means of preferred embodiments, the invention is not limited by the disclosed examples, and other variations may be derived therefrom by those skilled in the art without departing from the scope of the invention. It is therefore clear that a multitude of possible variations exist. It is also clear that the embodiments mentioned by way of example are truly only examples and should not be construed as limiting the scope, possible applications, or configuration of the invention in any way.Rather, the preceding description and the description of the figures enable the person skilled in the art to implement the exemplary embodiments in concrete terms, whereby the person skilled in the art, with knowledge of the disclosed inventive concept, can make various changes, for example with regard to the function or the arrangement of individual elements mentioned in an exemplary embodiment, without departing from the scope of protection defined by the claims and their legal equivalents, such as a further explanation in the description.

[0041] List of reference symbols 101 Main coil assembly

[0042] 102 electronic assembly

[0043] 103 heat pipe(s)

[0044] 104 Channel

[0045] 105 Power electronics 106 Main coil

Claims

Patent claims 1. Vehicle module CPM for converting electromagnetic energy of an electromagnetic field generated by a floor module GPM of an inductive vehicle charging system into electrical energy of an electric current, and for charging an electrical storage device and / or for operating an electrical load in the vehicle, wherein the vehicle module CPM comprises: a main coil assembly (101) with a main coil for converting the electromagnetic field into an alternating electrical current AC, and an electronic assembly (102) with power electronics (105) for converting the alternating electrical current AC into direct current DC, characterized in that one or more heat pipes (103) are provided for transferring / distributing heat generated locally in the main coil assembly (101) and / or in the electronic assembly (102) during an energy conversion operation,wherein the heat pipes (103) transfer the locally generated heat, in particular from the main coil assembly (101) to the electronic assembly (102) and vice versa, and the electronic assembly (102) has a channel (104) through which a refrigerant fluid can flow, which channel can be connected to an external heat exchanger, wherein the channel (104) is designed and constructed to transfer heat from the electronic assembly (102) to the refrigerant fluid.

2. Vehicle module CPM according to claim 1, characterized in that in regions of the main coil assembly (101) and / or the electronic assembly (102) which have a high local heat development during energy conversion operation, the heat pipes (103) are arranged in a higher density than in regions with low local heat development.

3. Vehicle module CPM according to one of claims 1 to 2, characterized in that at least some of the plurality of heat pipes (103) are arranged in two or more parallel planes in the vehicle module CPM.

4. Vehicle module CPM according to one of claims 1 to 3, characterized in that at least one heat pipe (103) is arranged in a housing material of a housing of the vehicle module CPM or is arranged directly on the housing.

5. Vehicle module CPM according to one of claims 1 to 4, characterized in that the main coil assembly (101) and the electronic assembly (102) are arranged spatially separated from one another within the vehicle module CPM and a wall is arranged between the two assemblies (101, 102), which is designed as a heat-conducting element.

6. Vehicle module CPM according to claim 5, characterized in that the heat-conducting element consists of a material with a thermal conductivity A > 10 W / (m *K) or A > 100 W / (m *K) or A > 150 W / (m *K) or A > 200 W / (m *K) or A > 300 W / (m *K).

7. Vehicle module CPM according to one of claims 1 to 6, characterized in that the main coil is embedded in a first thermally conductive material, the power electronics (105) is embedded in a second thermally conductive material which is thermally conductively connected to the first thermally conductive material.

8. Vehicle module CPM according to one of claims 1 to 7, characterized in that a housing of the vehicle module CPM has a structured outer surface which is in thermally conductive contact with the one or more of the heat pipes (103).

9. Inductive charging system for a vehicle for charging an electrical storage device of the vehicle, comprising at least one floor module GPM and one vehicle module CPM, wherein an energy transfer at least from Ground module GPM to the vehicle module CPM and wherein the vehicle module CPM is designed according to one of claims 1 to 8.

10. Vehicle with a vehicle module CPM according to one of claims 1 to 8.

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