Cpm vehicle module of an inductive charging system for a vehicle

Abstract

The invention relates to a CPM vehicle module of an inductive charging system for a vehicle, comprising a main coil assembly for converting the electromagnetic field into an electric alternating current; an electronic assembly for converting the electric alternating current into direct current, a heat dissipation means having an outer surface which is made of an electrically non-conductive plastic material and is in thermal contact with the main coil assembly and / or the electronic assembly, wherein the outer surface dissipates the heat generated during power conversion operation of the main coil assembly and the electronic assembly to an environment, and the outer surface (101) is formed by a plurality of structure elements (103) which are arranged separately on an unstructured smooth reference surface (102) of the outer surface (101) and are each raised over the reference structure (102).

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. Furthermore, 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 a vehicle module (CPM) of the same type. Furthermore, the invention relates to a vehicle with such a vehicle module (CPM).

[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 provide a vehicle module CPM with improved cooling at low cost.

[0007] 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 illustrated in the figures.

[0008] A first aspect of the invention relates to a vehicle module CPM of an inductive charging system for a vehicle, comprising a main coil assembly for converting a received electromagnetic field into an alternating electrical current; an electronic assembly for converting the alternating electrical current into direct current; and a heat dissipation means having an outer surface made of an electrically non-conductive plastic material, wherein the outer surface is in thermal contact with the main coil assembly and / or the electronic assembly, wherein the outer surface dissipates heat generated by the main coil assembly and / or the electronic assembly during power conversion operation to an environment, and the outer surface is formed by a plurality of structural elements arranged individually on an unstructured, smooth reference surface of the outer surface, each of which is raised above the reference surface.The isolated structural elements enlarge the surface and thus increase the heat transfer to the environment, especially the ambient air.

[0009] The structural elements are advantageously arranged exclusively evenly distributed or exclusively unevenly distributed or randomly distributed in at least part of the reference surface. The reference surface can in particular be a virtual reference surface assigned to the outer surface, from which all the structural elements extend in raised form. The vehicle module CPM advantageously has a housing with an outer housing surface, wherein the structured outer surface is present in a region of the outer housing surface which forms an underside of the vehicle when the vehicle module CPM is installed in the vehicle. Heat generated in the CPM during power conversion operation is dissipated to the ambient air via this outer housing surface arranged on the underside of the vehicle. The structural elements are preferably designed in such a way that in the event of an external mechanical effect on the outer surface of the housing outer surface, e.g.Structural elements remain largely undamaged by stone chips or by the vehicle hitting the outer surface of the housing.

[0010] Advantageously, the structural elements are arranged directly adjacent to one another as an array without defects or spaced apart from one another as an array without defects on the reference surface, preferably in rows and columns.

[0011] Advantageously, all structural elements are identical in terms of their 3D shape. In an alternative embodiment, at least some structural elements are designed differently in terms of their 3D shape.

[0012] Particularly advantageously, each structural element outer surface of a structural element emanating from the reference surface and the reference surface encloses an inclination angle (NW) from the range 0° < NW < 90° or 30° < NW < 60°, in particular the inclination angle NW = 45°. Furthermore advantageously, immediately adjacent, inclined structural element outer surfaces of different structural elements each enclose an angle (WE) from the range 90° < WE < 180° or 90° < WE < 150° or 90° < WE < 120° or the angle WE is in particular equal to 90°. This ensures that thermal radiation emanating from the structural element outer surfaces is essentially radiated into the environment and does not heat up adjacent structural element outer surfaces.

[0013] Particularly advantageously, at least one, several, or all structural elements are designed as pyramids, cones, or hipped roofs, with the respective base surface (of the pyramid, cone, or hipped roof) being arranged on the reference surface. The tips of the respective pyramids or cones can be rounded.

[0014] In another advantageous embodiment, at least one, several or all structural elements are designed as a truncated pyramid or as a truncated cone or mansard flat roof, wherein the respective base surface (of the truncated pyramid or the truncated cone or the mansard flat roof) is / are arranged on the reference surface.

[0015] The pyramids or truncated pyramids can advantageously have a triangular, rectangular, hexagonal or octagonal base.

[0016] An advantageous refinement of the CPM vehicle module is characterized by the fact that the outer surface predominantly or exclusively comprises structural elements, each designed as a pyramid, cone, or hipped roof. In the event of external mechanical impact on the outer surface of the housing, this creates a "soft" impact protection, albeit with lower abrasion resistance.

[0017] An advantageous development of the CPM vehicle module is characterized by the fact that the outer surface predominantly or exclusively comprises structural elements, each designed as a truncated pyramid, a truncated cone, or a mansard-shaped flat roof. In the event of external mechanical impact on the outer surface of the housing, this creates a "hard" impact protection with relatively higher abrasion resistance.

[0018] An advantageous development of the CPM vehicle module is characterized in that the outer surface, in one area, alternates between structural elements designed as pyramids, cones, or hipped roofs, and structural elements designed as truncated pyramids, truncated cones, or mansard flat roofs. In the event of external mechanical impact on the outer surface of the housing, this creates "medium" impact protection with medium abrasion resistance. The outer surface of the heat dissipation means is advantageously made of an electrically non-conductive material. The outer surface of the heat dissipation means is advantageously produced by molding, casting, or injecting a material into a mold. The outer surface of the heat dissipation means is advantageously produced by sintering a sinterable material in a mold.Advantageously, the outer surface of the heat dissipation means is produced by crosslinking a crosslinkable material in a mold. Advantageously, the outer surface of the heat dissipation means is produced additively in a layer-by-layer deposition process. Advantageously, the outer surface of the heat dissipation means comprises a polymer material. Advantageously, the outer surface of the heat dissipation means comprises a ceramic material. Advantageously, the outer surface of the heat dissipation means comprises a composite material. Advantageously, the outer surface of the heat dissipation means comprises a fiber-reinforced polymer matrix, wherein the fibers are made of an electrically non-conductive material. Advantageously, the outer surface of the heat dissipation means comprises a polymer matrix with particles dispersed therein, wherein the fibers are made of an electrically non-conductive material.Advantageously, the electrically non-conductive material is selected from at least one of the following materials: boron nitride, silicon carbide.

[0019] 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 ground pad module GPM and one vehicle module CPM, wherein energy is transferred between the ground pad module GPM and a vehicle module CPM and wherein the vehicle module CPM is designed as described above.

[0020] A third aspect of the invention relates to a vehicle with a vehicle module CPM as described above.

[0021] 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.

[0022] Shown are: Fig. 1 a schematic representation of a section of an outer surface of the heat dissipation means of a vehicle module CPM according to the invention, and

[0023] Fig. 2 is a schematic representation of a vehicle module CPM with a housing, which is simultaneously part of the heat dissipation means, which has a housing outer surface structured according to the invention, and

[0024] Fig. 3 is a schematic representation of an internal structure of a vehicle module CPM with main coil assembly 105 and electronic assembly 106.

[0025] Fig. 1 shows a schematic representation of a section of an outer surface of the heat dissipation means of a vehicle module CPM according to the invention. The outer surface and the structural elements 103 are made of an electrically non-conductive plastic material. The plastic material itself is advantageously a good heat conductor. This plastic material is in thermally conductive contact with the main coil assembly and / or the electronic assembly, with the outer surface 101 dissipating heat generated during power conversion operation of the main coil assembly 105 and the electronic assembly 106 to the ambient air.

[0026] On the flat reference surface 101 (here spanned by the two vectors shown), a plurality of individually arranged structural elements 103, each raised above the reference surface 102, are arranged in the form of adjacent pyramids with a square base area.

[0027] Each structural element outer surface 104 of a structural element 103 emanating from the reference surface 102 and the reference surface 102 enclose an inclination angle (NW) of approximately 45° in the present case. Accordingly, immediately adjacent (opposite one another) inclined structural element outer surfaces 104 of different structural elements 103 are each inclined to one another at an angle (WE) of approximately 90°. Thermal radiation emanating from the structural element outer surfaces 104 essentially does not heat the outer surface 101. Fig. 2 shows a schematic representation of a vehicle module CPM with a CPM housing in an oblique view. The structured surface of the CPM housing shown in Fig. 2 is arranged facing downwards on the vehicle floor when installed on the vehicle. The structured outer surface 101 of the CPM housing is also part of the heat dissipation means.The structured housing outer surface 101 has a plurality of pyramid-shaped structural elements 103, which are arranged in a matrix-like manner in rows and columns directly adjacent to one another.

[0028] Fig. 3 shows a schematic representation of an internal structure of a vehicle module CPM with the main coil assembly 105 and the electronic assembly 106. The main coil assembly has in particular a main coil, which in this case is designed as a flat coil.

[0029] 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. With knowledge of the disclosed inventive concept, the person skilled in the art can make various changes, for example, with regard to the function or 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. List of reference symbols.

[0030] 101 an outer surface of the heat dissipation agent

[0031] 102 Reference surface

[0032] 103 Structural element

[0033] 104 Structural element outer surface

[0034] 105 Main coil assembly

[0035] 106 electronic assembly

Claims

Patent claims 1. Vehicle module CPM of an inductive charging system for a vehicle, comprising a main coil assembly (105) for converting the electromagnetic field into an alternating electrical current; an electronic assembly (106) for converting the alternating electrical current into direct current, a heat dissipation means having an outer surface (101) made of an electrically non-conductive plastic material, which is in thermal contact with the main coil assembly and / or the electronic assembly, wherein the outer surface (101) dissipates heat generated during power conversion operation of the main coil assembly and the electronic assembly to an environment, and the outer surface (101) is formed by a plurality of structural elements (103) arranged individually on an unstructured, smooth reference surface (102) of the outer surface (101) and each raised above the reference surface (102).

2. Vehicle module CPM according to claim 1, wherein structural elements (103) are arranged exclusively evenly distributed or unevenly distributed in at least a part of the reference surface (102).

3. Vehicle module CPM according to claim 1 or 2, wherein the vehicle module CPM has a housing with a housing outer surface, wherein the structured outer surface (101) is present in a region of the housing outer surface which forms a vehicle underside in the installed state of the vehicle module CPM in the vehicle.

4. Vehicle module CPM according to one of claims 1 to 3, wherein the structural elements (103) are each arranged directly adjacent to one another as an array without defects on the reference surface (102).

5. Vehicle module CPM according to one of claims 1 to 3, wherein the structural elements (103) are each arranged spaced apart from one another as an array without defects on the reference surface (102).

6. Vehicle module CPM according to one of claims 1 to 3, wherein the structural elements (103) are arranged in rows and columns on the reference surface (102).

7. Vehicle module CPM according to one of claims 1 to 6, wherein each structural element outer surface (104) of a structural element (103) extending from the reference surface (102) and the reference surface (102) enclose an angle of inclination (NW) from the range of 0° < NW < 90° or 30° < NW < 60° or the angle of inclination (NW) is 45°.

8. Vehicle module CPM according to one of claims 1 to 7, wherein immediately adjacently arranged, inclined structural element outer surfaces (104) of different structural elements (103) each enclose an angle (WE) from the range 90° < WE < 180° or 90° < WE < 150° or 90° < WE < 120° or the angle (WE) is in particular equal to 90°.

9. Vehicle module CPM according to one of claims 1 to 8, wherein at least one, several or all structural elements (103) are each designed as a pyramid or as a cone or hipped roof, wherein the respective base surface of the pyramid or the cone or the hipped roof is / are arranged on the reference surface (102).

10. Vehicle module CPM according to one of claims 1 to 9, wherein at least one, several or all structural elements (103) are each designed as a truncated pyramid or as a truncated cone or mansard flat roof, wherein the respective base surface of the truncated pyramid or the truncated cone or the mansard flat roof is / are arranged on the reference surface (102).

11. Inductive charging system for a vehicle for charging an electrical storage device of the vehicle, comprising at least one floor module GPM and a vehicle module CPM, wherein an energy transfer takes place between the floor module GPM and the vehicle module CPM and wherein the vehicle module CPM is designed according to one of claims 1 to 10.

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

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