Main coil assembly for a ground module gpm or for a vehicle module cpm of an inductive charging system for a vehicle

Abstract

The invention relates to a main coil assembly for a ground module (GPM) or for a vehicle module (CPM) of an inductive charging system for a vehicle, the main coil assembly comprising a main coil (101). The invention is characterised in that the main coil (101) is designed having at least one current conductor (102), the at least one current conductor (102) is arranged in a volume, through which a fluid can flow, between a first boundary surface (103) and a second boundary surface (104) of the main coil assembly such that fluid can flow around the current conductor (102), and the at least one current conductor (102) is guided / held in a predetermined coil geometry and in a predetermined coil position in the volume by means of individual and spaced-apart guiding and / or holding elements (105).

Description

[0001] Main coil assembly for a ground module GPM or for a vehicle module CPM of an inductive charging system for a vehicle

[0002] The invention relates to a main coil assembly for a ground module GPM (Ground Pad Module) or for a vehicle module CPM (CPM for Car Pad Module) of an inductive charging system for a vehicle, wherein the main coil assembly comprises at least one main coil. Typically, in inductive charging systems, energy is transferred inductively 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 or for operating 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.

[0003] The GPM is typically installed outside the vehicle on the ground, while the CPM is mounted on the vehicle, usually on the underside. An electromagnetic coupling between the main coil of the GPM and the main coil of the CPM enables energy transfer from the GPM to the CPM, thus charging the vehicle's battery.

[0004] Both the GPM and the CPM typically comprise a power electronics module and a main coil module. To enable optimal electromagnetic coupling between the two main coils, the main coil of the GPM and the main coil of the CPM must be optimally positioned relative to each other, and energy can be inductively transferred to a main coil of the vehicle module CPM or vice versa (bidirectionally) via a main coil of the ground module GPM.

[0005] The object of the invention is to provide a main coil assembly for a ground module GPM or for a vehicle module CPM of an inductive charging system for a vehicle, which enables a simple manufacturing process, lower material usage, reliable product quality and better cooling.

[0006] 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.

[0007] The problem is solved with a main coil assembly for a floor module GPM or for a vehicle module CPM of an inductive charging system for a vehicle, wherein the main coil assembly comprises a main coil. The main coil assembly is further characterized in that the main coil is designed with at least one current conductor, the at least one current conductor being arranged in a volume through which a fluid can flow, between a first boundary surface and a second boundary surface of the main coil assembly, such that the current conductor itself can be flowed around by the fluid, and the at least one current conductor is guided / held in the volume by means of individual and spaced-apart guide and / or holding elements in a predetermined coil geometry and in a predetermined coil position.

[0008] The main coil is preferably designed as a flat coil. Advantageously, the at least one current conductor of the flat coil is arranged in one plane. If the main coil has more than one current conductor, the multiple current conductors can advantageously be arranged in several planes aligned parallel to one another.

[0009] The first and second boundary surfaces are advantageously aligned substantially parallel to one another. Advantageously, the first boundary surface and / or the second boundary surface are fluid-tight. If both boundary surfaces are fluid-tight, both an inflow of fluid and an outflow of fluid occur laterally through side surfaces that are perpendicular to the first and second boundary surfaces, for example. Advantageously, the side surfaces are designed such that at least two regions of the side surfaces allow fluid to flow in or out, while the remaining side surface regions are fluid-tight. The fluid is advantageously ambient air.

[0010] Advantageously, a flow generator, such as a fan, propeller, or similar, is present in the main coil assembly or in a neighboring assembly. This generator imparts a flow velocity to the fluid, at which the fluid flows into or out of the volume. Advantageously, the flow of the fluid within the volume is controlled by targeted local flow manipulation. Such flow manipulations include, for example, targeted changes in the local flow resistance in the flow-through volume and / or targeted changes in the local heat transfer between the fluid and the boundary surfaces of the fluid flow and / or targeted delays or stimulations of local flow separation (e.g., targeted stimulation of laminar to turbulent flow) in the flow-through volume, etc.

[0011] It is advantageous to arrange flow-guiding elements (such as profiled elements) in the flow-through volume to specifically influence the local flow direction. These flow-guiding elements cause a targeted change in the flow direction in the wake of the respective element.

[0012] Essential for improved cooling or improved heat dissipation from the main coil assembly is that the current conductor is arranged in the volume in such a way that fluid can flow around it. Advantageously, a surface of the at least one current conductor of the main coil can be flowed around by fluid, i.e., up to, if applicable, those surface areas of the current conductor that are covered by the guide and / or support elements. Advantageously, the at least one current conductor is arranged in the volume in a substantially "free-floating" manner by means of the guide and / or support elements.

[0013] In an advantageous embodiment, the at least one current conductor is arranged adjacent to either the first or the second boundary surface. In this case, the fluid advantageously flows around the surface of the at least one current conductor up to the contact surface of the current conductor on the respective boundary surface and, if applicable, those surface areas of the current conductor that are covered by the guide and / or support elements.

[0014] The guide and / or holding elements arranged individually and spaced apart from one another serve, on the one hand, to guide / hold the at least one current conductor of the main coil in a predetermined coil geometry and, on the other hand, to guide / hold it in a predetermined coil position or current conductor position in the volume.

[0015] Advantageously, the guide and / or support elements are designed at least partially as spacers between the first boundary surface and the second boundary surface, connecting them. Advantageously, the guide and / or support elements are cylindrical in shape. Advantageously, the guide and / or support elements are designed at least partially for the local fixation of the current conductor to the guide and / or support elements. For example, the guide and / or support elements each have a clip or other fastening mechanism for the local fixation of the current conductor.

[0016] Particularly advantageously, the guide and / or support elements are designed to specifically influence the flow direction in the flow wake of a respective guide and / or support element, so that the flow direction upstream of a guide and / or support element and the flow direction downstream in the wake of the guide and / or support element are specifically different. The flow in the volume is preferably influenced in such a way that the fluid has the highest flow velocities and thus the greatest mass throughput in those areas of the volume where heat production by the main coil is highest during operation.

[0017] An advantageous further development is characterized in that the at least one current conductor consists of at least one stranded wire which has a plurality of individual wires twisted together, wherein the individual wires each have an electrically non-conductive coating, and the stranded wire has a sheath made of plastic and / or silk.

[0018] The conductor advantageously consists of several twisted strands, each of which has a sheath made of plastic and / or silk. The sheathing is advantageously constructed from multiple layers of different materials. The sheathing advantageously consists of one or more of the following materials:

[0019] ETFE: refers to ethylene-tetrafluoroethylene plastics

[0020] PTFE: refers to polytetrafluoroethylene plastics

[0021] FEP: refers to fluoroethylene-propylene plastics

[0022] Polymer alloy: refers to polymer alloys that are created by mixing (compounding) two or more polymers or copolymers

[0023] Polyamide: refers to linear polymers with regularly repeating

[0024] Amide bonds along the main chain

[0025] FR4: FR-4, or FR4, refers to a class of flame-resistant and flame-retardant composite materials consisting of epoxy resin and fiberglass fabric. The material(s) forming the sheath of the strand(s) of the current conductor is / are advantageously selected to ensure flammability in accordance with the UL94 V-0 standard "Tests for Flammability of Plastic Materials for Parts in Devices and Appliances." This standard describes a method for assessing and classifying the flammability of plastics. It has been adopted with identical content into the standards IEC / DIN EN 60695-11-10 and -20 and the Canadian CAN / CSA C 22.2 No.017.

[0026] The classification is based on the thickness of the specimen tested, as HB (horizontal burning test) and V-0, V-1, V-2, 5VA, and 5VB (vertical burning test). These, in order of severity, represent:

[0027] • HB: slow burning of a horizontally clamped sample (self-extinguishing or if the thickness is <3 mm; rate <75 mm / min (HB75); if the thickness is 3...13 mm; rate <40 mm / min (HB40)).

[0028] • V-2: Extinguishing of a vertically clamped sample within 30 seconds. Burning droplets of molten plastic are permitted.

[0029] • V-1: Same as V-2, except that flaming droplets of molten plastic are not permitted. A maximum of 60 seconds of afterglow is allowed.

[0030] • V-0: as V-1, but the flame is extinguished within 10 seconds. Afterglow for a maximum of 30 seconds. The sheath of a conductor held by a guide and / or mounting element does not experience any wear due to thermal expansion of the conductor; the sheath has a material durability of at least 15 years; the breakdown voltage of the sheathed conductor is at least 3 kV; the sheath is resistant to substances found in a road environment, in particular petrol, diesel, synthetic oils, natural oils, salt water, cleaning fluids, brake fluids, etc.; water absorption into the sheath is as low as possible - under no circumstances must the breakdown voltage fall below 3 kV; the sheathed conductor is thermally stable in the range -40 °C to 100 °C; the sheathed conductor allows a minimum bending radius of 70 mm; the sheathed conductor is mechanically resistant to particles carried in the fluid flow; the sheathed conductor is resistant to UV radiation; the sheathed conductor is resistant to ozone and other harmful gases occurring in the atmosphere near the ground.

[0031] It is advantageous if the sheath of the current conductor has the highest possible thermal conductivity.

[0032] A particularly preferred embodiment is characterized in that the current conductor consists of a plurality of stranded wires twisted together, each having a plurality of individual wires twisted together, wherein the individual wires each have an electrically non-conductive coating, and the twisted strands have a first sheath made of a first polymer alloy, a second sheath made of a second polymer alloy applied thereto.

[0033] Further advantages, features, and details will become apparent from the following description, in which at least one embodiment is described in detail—possibly with reference to the drawings. Identical, similar, and / or functionally equivalent parts are provided with the same reference numerals.

[0034] They show:

[0035] Fig. 1 is a schematic diagram of a main coil assembly for a ground module GPM or for a vehicle module CPM of an inductive charging system for a vehicle, wherein the main coil assembly comprises a main coil 101 arranged on a first boundary surface 103, in an oblique view,

[0036] Fig. 2 is a schematic diagram of a detailed view of the main coil 101 arranged on the first boundary surface 103 in an oblique view, and

[0037] Fig. 3 is a schematic diagram of the main coil 101 arranged between a first boundary surface 103 and a second boundary surface 104 in a side view.

[0038] Fig. 1 shows a schematic diagram of a main coil assembly according to the invention for a ground module (GPM) or for a vehicle module (CPM) of an inductive charging system for a vehicle. The main coil assembly comprises a main coil 101 arranged on a first boundary surface 103. The main coil 101 is designed with a current conductor 102 as a flat coil with a rounded rectangular-spiral coil geometry. The current conductor 102 has electrical connections (marked by circles) at its two ends.

[0039] The current conductor 102 is arranged in a volume through which a fluid, in this case ambient air, can flow between the first boundary surface 103 and a second boundary surface 104 (not shown) of the main coil assembly in such a way that the ambient air can flow around the current conductor 102.

[0040] Furthermore, the at least one current conductor 102 is guided and held in the volume by means of individual and spaced-apart guide and / or holding elements 105 in the said coil geometry and in a predetermined coil position.

[0041] Fig. 2 shows a schematic diagram of a detailed view of the main coil 101 arranged on the first boundary surface 103 in an oblique view. The cylindrical guide and / or support elements 105 can be seen, whereby these cylindrical guide and / or support elements 105 guide and support the current conductor 102 in the predetermined coil geometry. Also visible are guide and / or support elements 105 designed as cable clips, which support the current conductor

[0042] 102 in a predetermined position. Finally, a guide and / or support element 105* has a shape that, in addition to the guide and support function of the current conductor 102, is designed to specifically influence the flow direction of the fluid, ie, the flowing ambient air.

[0043] Fig. 3 shows a schematic diagram of the main coil 101 arranged between a first boundary surface 103 and a second boundary surface 104 in a side view. In the volume through which ambient air can flow between the first boundary surface

[0044] 103 and second boundary surface 104, the current conductor 102 of the main coil 101 is arranged adjacent to the first boundary surface.

[0045] 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.

[0046] List of reference symbols

[0047] 101 Main coil

[0048] 102 conductors

[0049] 103 first boundary surface

[0050] 104 second boundary surface

[0051] 105 Guide and / or support elements

Claims

Patent claims 1 . Main coil assembly for a ground module (GPM) or for a vehicle module (CPM) of an inductive charging system for a vehicle, wherein the main coil assembly comprises a main coil (101), characterized in that - the main coil (101) is designed with at least one current conductor (102), - the at least one current conductor (102) is arranged in a fluid-flowable Volume between a first boundary surface (103) and a second boundary surface (104) of the main coil assembly is arranged such that the current conductor (102) can be flowed around by the fluid, and - the at least one current conductor (102) is guided / held in the volume by means of individual and spaced-apart guide and / or holding elements (105) in a predetermined coil geometry and in a predetermined coil position.

2. Main coil assembly according to claim 1, characterized in that the guide and / or holding elements (105) are designed at least partially as spacers between the first boundary surface (103) and the second boundary surface (104) and connecting them.

3. Main coil assembly according to claim 1 or 2, characterized in that the guide and / or holding elements (105) are designed as guide elements for guiding the fluid.

4. Main coil assembly according to one of claims 1 to 3, characterized in that the guide and / or holding elements (105) are at least partially designed for the local fixing of the current conductor (102).

5. Main coil assembly according to one of claims 1 to 4, characterized in that the at least one current conductor (102) consists of at least one stranded wire which has a plurality of individual wires twisted together, wherein the individual wires each have an electrically non-conductive coating, and the stranded wire has a sheath made of plastic and / or silk.

6. Main coil assembly according to claim 5, characterized in that the current conductor (102) consists of a plurality of stranded wires twisted together, wherein the twisted wires have a sheath made of plastic and / or silk.

7. Main coil assembly according to claim 5 or 6, characterized in that the sheath is constructed in multiple layers from different material layers.

8. Main coil assembly according to one of claims 5 to 7, characterized in that the sheath consists of one or more of the following materials: - ETFE - PTFE - FEP - Polymer alloy - Polyamide - FR4 9. Main coil assembly according to one of claims 1 to 4, characterized in that the current conductor (102) consists of a plurality of strands twisted together, each having a plurality of individual wires twisted together, wherein the individual wires each have an electrically non-conductive coating, and the twisted strands have a first sheath made of a first polymer alloy, a second sheath made of a second polymer alloy applied thereto.

10. Main coil assembly according to one of claims 1 to 9, characterized in that the fluid is ambient air.

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