Power Transformer Assembly

Abstract

The present invention relates to a wireless charger for charging a high-voltage (HV) battery of a vehicle, comprising: a coil configured to wirelessly receive an oscillating magnetic field from an external transmitter, thereby generating an alternating current (AC); a ferrite disposed adjacent to the coil; a cooling channel disposed adjacent to at least one of the ferrite and the coil, the cooling channel configured to provide a flow of coolant; electrical components configured to charge the HV battery based on the AC; and a metal cover separating the coil and ferrite from the electrical components, at least one of the electrical components being disposed adjacent to the metal cover, the wireless charger further comprising a non-conductive part configured to at least partially form the cooling channel and separate the coil and ferrite from the metal cover.

Description

[Technical field]

[0001]

[0001] The present invention relates to a power transformer assembly for converting electromagnetic power of an oscillating electromagnetic field into electrical power or usable current for charging an electrical storage device or energizing an electrical load. The power transformer assembly comprises a magnetic assembly for receiving the oscillating electromagnetic field and converting the oscillating electromagnetic field into an alternating current, and an electronic assembly for receiving the alternating current and converting the alternating current into an electrical power or usable current. The power transformer assembly further comprises heat dissipation means for dissipating heat generated by the electronic assemblies during their respective power conversion operations.

[0002]

[0002] A power transformer assembly, also called a wireless charger module, may be used to charge a vehicle's high voltage (HV) battery. Such a module, sometimes called a car pad module (CPM), may receive an oscillating magnetic field from an external transmitter, sometimes called a ground pad module (GPM), and convert the oscillating electromagnetic, primarily magnetic, current into an alternating current, which is converted (typically rectified) into a current (typically direct current) that is used to charge the HV battery. [Background technology]

[0003]

[0003] The battery of an electric vehicle can be charged using alternating current (AC) or direct current (DC) energy transfer. DC energy transfer is typically performed using a high-power converter located at a dedicated charging point. DC charging is typically faster than AC charging, but because the installation of DC charging points is expensive and the existing network capacity in residential areas is usually weak, DC charging points are typically located in remote locations and are not installed in homes or residential areas, making them less convenient for end users.

[0004]

[0004] On the other hand, AC charging is very important for residential areas and (semi-)public urban areas. A typical AC charger can provide a maximum charging power of 22 kW. AC charging systems can be divided into wired charging systems and wireless charging systems, and wireless charging systems are mainly embodied as inductive charging systems (ICS). Wired AC chargers are typically integrated into electric vehicles and are also called on-board chargers. An ICS typically comprises two separate modules, often called the Ground Pad Module (GPM) and the Car Pad Module (CPM).

[0005]

[0005] The GPM is installed outside the electric vehicle, while the CPM is installed inside the electric vehicle, usually on the bottom side of the vehicle. Electromagnetic interaction between the GPM and the CPM allows energy transfer from the GPM to the CPM, which is then used to charge the battery of the electric vehicle. Wireless charging systems are often more convenient for users because no manual intervention is typically required to start the battery charging process, other than parking the vehicle above the GPM. On the other hand, wired charging systems require users to connect the electric vehicle to the power grid via a cable.

[0006]

[0006] The term "GPM" as used herein should be understood to be equivalent to the term "wireless charging supply" or simply "supply" as used herein. The term "CPM" as used herein should be understood to be equivalent to the term "wireless charger" or simply "charger" as used herein. Also, in this document, the terms "power transformer assembly" and "wireless charger" or "wireless charger module" are used interchangeably.

[0007]

[0007] With regard to cooling, it is important to understand that CPMs have two heat generating regions: (a) the electronic assembly (power electronics), which produces a large amount of heat but which is relatively concentrated in specific locations (high density), and (b) the magnetic assembly (coils and ferrites), which produces less heat that is relatively well distributed (low density). Prior art cooling systems for such CPMs are not well adapted to these conditions and are relatively difficult and therefore expensive to manufacture. OBJECTS OF THE INVENT

[0008] SUMMARY OF THE PRESENT EMBODIMENTS It is therefore an object of the present invention to provide a power transformer assembly which meets the overall cooling requirements, particularly of electronic assemblies, and which can be manufactured easily and at relatively low cost. Summary of the Invention

[0009]

[0009] The object of the present invention is to provide a power transformer assembly for converting the electromagnetic power of an oscillating electromagnetic field into electrical power of a current for charging an electrical storage device or energizing an electrical load, the power transformer assembly comprising: a magnetic assembly for receiving an oscillating electromagnetic field and converting the oscillating electromagnetic field into an alternating current; _ an electronic assembly for receiving alternating current and converting the alternating current into electric current; Equipped with A power transformer assembly, the power transformer assembly comprising heat dissipation means for dissipating heat generated by the magnetic assembly and the electronic assembly during their respective power conversion operations, a) a heat dissipation means is disposed between the magnetic assembly and the electronic assembly and is in thermal contact with the magnetic assembly and the electronic assembly; _b) The heat dissipation means is a first part in thermal contact with the magnetic assembly; a second component in thermal contact with the electronic assembly; Including, c) the first part includes a first material and / or has a first structure adapted to dissipate heat flow from the magnetic assembly; d) the second component includes a second material different from the first material and / or has a second structure different from the first structure adapted to dissipate heat flow from the electronic assembly. This is achieved by a power transformer assembly, characterized in that

[0010] As a result, a first component in thermal contact with the magnetic assembly and including a first material and / or a first structure adapted to dissipate heat flow from the magnetic assembly provides a first portion for the overall heat dissipation from the power transformer assembly. Similarly, a second component in thermal contact with the electronic assembly and including a second material different from the first material and / or having a second structure different from the first structure adapted to dissipate heat flow from the electronic assembly provides a second portion for the overall heat dissipation from the power transformer assembly. In other words, in a power transformer assembly, if the magnetic assembly is a first type of heat source and the electronic assembly is a second type of heat source, the present invention allows for heat source specific heat dissipation by providing the first component as a first type of heat sink and the second component as a second type of heat sink. By allowing the materials and / or structures of the first component (first type of heat sink) and the second component (second type of heat sink) to be different from each other, each of the first and second components needs to meet the heat dissipation requirements of the magnetic assembly (first type of heat source) and the electronic assembly (second type of heat source), respectively. Thus, the first part may be provided with a first material and a first structure that primarily meets the heat dissipation requirements of the magnetic assembly, and the second part may be provided with a second material and a second structure that primarily meets the heat dissipation requirements of the electronic assembly. The specific heat dissipation requirements for each of the first and second parts may thus be minimal, which allows significant savings to be achieved. For example, savings may be achieved by choosing a material with low thermal conductivity, which may be compensated for by providing this material with a special structure that helps to improve heat flow. The present invention further facilitates greater flexibility in the design of power transformers and reduced associated parts.

[0011]

[0011] Preferably, the first component includes a first material having a first thermal conductivity and the second component includes a second material having a second thermal conductivity, the second thermal conductivity being greater than the first thermal conductivity.

[0012]

[0012] Preferably, the thermal conductivity of the second material is greater than 100 W / (m·K), which ensures sufficient heat flow from the electronic assembly as a heat source having concentrated hot spots and relatively high temperatures.

[0013]

[0013] Preferably, the first material and / or the second material is a metal, a metal alloy, a polymer, a polymer blend, or a composite material.

[0014]

[0014] Preferably, the first material is a polymer or a polymer blend.

[0015]

[0015] Preferably, the second material is a metal, a metal alloy, or a composite material.

[0016] In a preferred embodiment, the first component comprises a portion defining a duct for a heat transfer fluid (coolant), which allows the first component to be placed in fluid connection with a coolant circuit, the duct of the first component being preferably part of the coolant circuit.

[0017]

[0017] Preferably, the first part having the portion defining said duct is produced by forming (shaping) a material in a mould, which makes it possible to reduce manufacturing costs.

[0018]

[0018] The first part having the portion defining the duct may be made by molding (casting, injecting) a moldable material in the mold.

[0019]

[0019] The first part having a portion defining the duct may be made by sintering a sinterable material in the mould.

[0020]

[0020] The first part having a portion defining the duct may be made by crosslinking a crosslinkable material in the mould.

[0021]

[0021] Preferably, the first part having the portion defining said duct is fabricated additively layer by layer, which allows complex geometries for manufacturing the first part, which lends itself to efficient heat transfer from the magnetic assembly (coil, ferrite) as a more evenly distributed heat source to the first part as a heat sink with the heat transfer fluid (coolant) flowing through the duct.

[0022]

[0022] Preferably, the first part comprises a polymer, which allows the first part having the duct geometry to be manufactured by moulding, which is low cost.

[0023]

[0023] The first component may comprise a polymer matrix having particles dispersed therein, said particles being selected from the group comprising metal particles and graphite particles, which particles enhance the electrical conductivity of the polymer.

[0024]

[0024] Preferably, the second component comprises a solid metallic material, which ensures sufficient heat flow from the electronic assembly as a heat source having concentrated hot spots and relatively high temperatures, in addition, the second component provides additional mechanical strength to the overall dissipation means.

[0025]

[0025] Preferably, the second component comprises a porous metal material, which makes it possible to reduce the amount of metal material required without any significant decrease in the thermal conductivity and mechanical strength of the second component. Therefore, it is possible to reduce the weight and material costs compared to solid metal materials.

[0026] In a preferred embodiment, the second component includes a metal layer that contributes to the equalization of local temperature peaks / hot spots in the electronic assembly by lateral heat flow along the metal layer.

[0027]

[0027] Preferably, the magnetic assembly comprises a coil.

[0028]

[0028] Preferably, the magnetic assembly includes a material adjacent the coil, said material having a magnetic permeability of 1 or greater.

[0029]

[0029] Preferably, the material adjacent the coil is ferrite.

[0030]

[0030] Preferably, the electronic assembly comprises power electronic components.

[0031]

[0031] Preferably, the heat dissipation means includes a third component disposed between the first component and the magnetic assembly. As previously mentioned, the first component may be provided with a first material and a first structure that primarily serves only the heat dissipation requirements of the magnetic assembly, and the second component may be provided with a second material and a second structure that primarily serves only the heat dissipation requirements of the electronic assembly. The third component may further modify the overall heat dissipation characteristics provided by the first and second components. In addition, each of the three components may be provided with its own material and geometry. _Therefore, the overall heat dissipation means of the power transformer assembly or wireless charger according to the present invention can be modularly assembled using two or three heat dissipation components to obtain specific heat dissipation and mechanical properties of the overall heat dissipation means.

[0032]

[0032] Preferably, the third part comprises a solid metallic material, which ensures sufficient heat flow from the magnetic assembly, and also provides additional mechanical strength to the overall dissipation means.

[0033]

[0033] Preferably, the third component comprises a porous metal material. Again, this allows a reduction in the amount of metal material required without any significant reduction in the thermal conductivity and mechanical strength of the third component, thus reducing weight and material costs relative to solid metal materials.

[0034]

[0034] Preferably, the third component includes a metal layer, again contributing to the equalization of local temperature non-uniformities in the magnetic assembly by lateral heat flow along the metal layer.

[0035]

[0035] Preferably, a three-part sandwich arrangement consisting of a first part, a second part and a third part is placed between the magnetic assembly and the electronic assembly and is in thermal contact with each of the magnetic assembly and the electronic assembly. The three-part sandwich arrangement consisting of the first, second and third parts defined above helps to improve the mechanical strength of the overall heat dissipation means of this sandwich type. Preferably, this sandwich structure is placed between the magnetic assembly (first heat source) and the electronic assembly (second heat source) and is in thermal contact with each of the magnetic assembly (first heat source) and the electronic assembly (second heat source). Preferably, the second and third parts have a higher mechanical strength than the first part between them, the second and third parts. This provides an overall heat dissipation means with high bending stiffness. Preferably, the second and third parts are made of solid or porous metal layers, while the first part between them may be made of a polymer. The first part may be a web structure, preferably a perforated honeycomb structure, which allows the flow of coolant while providing high bending stiffness at a small weight.

[0036]

[0036] Preferably, the duct for the heat transfer fluid defined by the material of the first component comprises a plurality of flow obstacles extending across the duct.

[0037] At least some of the flow obstructions may be integrally formed with the first component.

[0038] At least some of the flow obstructions may be integrally formed with the second component.

[0039] At least some of the flow obstructions may be integrally formed with the third component.

[0040]

[0040] Preferably, the first part comprises a functional portion integrally formed with the duct-defining material of the first part.

[0041]

[0041] These functional parts may include at least one of a heat transfer fluid (coolant) inlet, a heat transfer fluid (coolant) outlet, a snorkel (breathing element), and an interface structure.

[0042]

[0042] For example, the present invention relates to a wireless charger for charging a high-voltage (HV) battery of a vehicle, comprising: a coil configured to wirelessly receive an oscillating magnetic field from an external transmitter and thereby generate an alternating current; a ferrite disposed adjacent to the coil; a cooling channel disposed adjacent to at least one of the ferrite and the coil, the cooling channel configured to provide a flow of coolant; electrical components configured to charge the HV battery based on AC; and a metal cover separating the coil and ferrite from the electrical components, at least one of the electrical components being disposed adjacent to the metal cover, wherein the wireless charger further comprises a non-conductive part configured to at least partially form the cooling channel and separate the coil and ferrite from the metal cover.

[0043] In some embodiments, the cooling channels are at least partially defined by recesses machined or formed in the non-conductive component.

[0044] In some embodiments, the cooling channels are formed by closing off the recesses with a metal cover abutting the non-conductive component.

[0045]

[0045] In some embodiments, the wireless charger further comprises a plate, and the cooling channel is formed by the plate closing the recess by abutting the non-conductive part, the plate separating the non-conductive part from the metal cover.

[0046] In some embodiments, the cooling channels are incorporated into the non-conductive components.

[0047] In some embodiments, the metal cover is at least a part of the housing of the HV battery.

[0048] In some embodiments, the metal cover includes a structure for enlarging the heat sink, the structure being immersed in the cooling channel.

[0049]

[0049] In some embodiments, the wireless charger further comprises a coolant inlet and a coolant outlet, both of which are machined or formed into the non-conductive component.

[0050] In some embodiments, the metal cover is bonded to the non-conductive component.

[0051] In some embodiments, the metal cover is flat at least in the areas adjacent the non-conductive components.

[0052] In some embodiments, the non-conductive parts are made of plastic.

[0053] In some embodiments, the coil and ferrite are combined in one potting.

[0054]

[0054] In some embodiments, the wireless charger further comprises a coil cover made of plastic, the potting being embedded within the coil cover, and the coil cover being configured to be joined with a non-conductive component.

[0055]

[0055] In some embodiments, the wireless charger further comprises a sealing lip that bounds or surrounds the cooling channel.

[0056]

[0056] In some embodiments, the metal cover is made of aluminum and is configured to shield the vehicle from oscillating magnetic fields. [Brief description of the drawings]

[0057]

[0057] By way of example only, preferred embodiments of the invention will now be described more fully hereinafter with reference to the accompanying drawings, in which:

[0058] [Figure 1]

[0058] Figure 1 shows in a top view a garage in which a vehicle is parked above a wireless charging supply that is external to the vehicle and has a transmitter for transmitting an oscillating magnetic field.

[0059] [Diagram 2]

[0059] Figure 2 shows an expanded view of Figure 1, illustrating a wireless charging supply and a wireless charger for charging a vehicle's high voltage (HV) battery.

[0060] [Diagram 3]

[0060] Figure 3 shows the charger of Figure 2 in an enlarged 3D view.

[0061] [Figure 4]

[0061] Figure 4 shows a cross-sectional view of a prior art charger.

[0062] [Diagram 5]

[0062] FIG. 5 shows an exemplary embodiment (first embodiment) of the charger of the present invention.

[0063] [Figure 6]

[0063] Figure 6 shows diagrammatically a further embodiment (second embodiment) in which the metal cover is "donated" by the housing of the HV battery.

[0064] [Figure 7] FIG. 7 illustrates an exemplary embodiment (third embodiment) of a wireless charger with a coolant inlet and a coolant outlet machined or formed into the non-conductive part.

[0065] [Figure 8A] FIG. 8A shows another embodiment (fourth embodiment) in a schematic cross-sectional view. [Figure 8B]

[0065] FIG. 8B is a perspective view that shows another embodiment (fourth embodiment).

[0066] [Figure 9A] FIG. 9A shows a further embodiment (fifth embodiment) diagrammatically in cross section. [Figure 9B] FIG. 9B shows a further embodiment (fifth embodiment) diagrammatically in a perspective view. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0067]

[0067] Figure 1 shows a garage 1 in a top view, where a vehicle 2 is parked on a wireless charging supply 3 that is external to the vehicle 2 and has a transmitter for transmitting an oscillating magnetic field. The supply 3 can be seen as the vehicle 2 is depicted as being transparent. Such a charging solution is very convenient and saves the driver the trouble of plugging and unplugging the charging cable.

[0068]

[0068] Figure 2 is an enlarged view of Figure 1 and shows a wireless charging supply 3 and also a wireless charger 4 for charging the high voltage (HV) battery of the vehicle 2, "floating" above the supply 3. Said charger 4 is fitted to the vehicle, which means that the rest of the vehicle is hidden in this view.

[0069]

[0069] Figure 3 shows the charger 4 in an enlarged 3D view.

[0070]

[0070] Figure 4 shows a cross-sectional view of a charger 5 according to the prior art. The charger 5 has a coil 6 configured to wirelessly receive the oscillating magnetic field from an external transmitter included in the wireless charging supply 3. The oscillating magnetic field induces an alternating current (AC) in the coil. A ferrite 7 is arranged adjacent to the coil 6. A cooling channel 8 is arranged adjacent to the ferrite 7 and configured to provide a flow of coolant. The flowing coolant cools a metal cover 9 in which the cooling channel is integrated. An electrical component 10 configured to charge the HV battery based on AC is arranged adjacent to the metal cover for heat dissipation. The metal cover 9 separates the coil 6 and the ferrite 7 from the electrical component 10. The coil 6 and the ferrite 7 are embedded in a potting 11 protected by a coil cover 12. The potting 11 and the coil cover 12 are typically made of plastic.

[0071]

[0071] The disadvantage of the configuration described in Fig. 4 is that the arrangement of the coil / ferrite 6 / 7 is very close to the metal cover 9 and is not insulated against the metal cover 9, resulting in relatively high eddy current losses. Also, more specifically, the configuration shown in Fig. 4 causes very complex deformations due to thermal expansion, since the metal cover 9 is hooked within the magnetic assembly 11 / 12, which, as a plastic part, has a significantly different thermal expansion coefficient than the metal cover 9. These relative movements can cause material fatigue in the long term. Moreover, the complex geometry of the metal cover 9 is difficult and expensive to achieve.

[0072]

[0072] Despite the differences as illustrated in Fig. 5, the wireless charger according to the invention has the components as described above in Fig. 4. The associated one or more electrical components 10 (or 14 in Fig. 5) may include at least one of a tuner, a rectifier, a DC / DC converter and an EMC filter. Furthermore, the wireless charger 13 may include a wireless data receiver (not shown) that allows control of the charging process, in particular of the DC / DC converter. Another optional component is a sensor (not shown) that may be used to determine the positioning of the charger 13 relative to the power supply (indicated by reference 3 in Figs. 1 and 2) above which the vehicle is parked.

[0073]

[0073] Figure 5 shows an exemplary embodiment of the charger of the invention. The coil 15 and the ferrite 16 are embedded in a potting 17 which is embedded in a coil cover 18. The coil cover 18 has recesses 19 for receiving lugs 20 of the potting 17. The recesses 19 are further adapted to receive lugs 21 belonging to a non-conductive part 22. The non-conductive part 22 may be manufactured, for example, from plastic, in particular by injection molding. Advantages of this part 22 include: (a) part 22 is in direct contact with potting 20, which has a similar coefficient of thermal expansion, and therefore causes little or no relative movement between the two components due to thermal expansion; (b) part 22 is lighter than parts known from prior art chargers; (c) part 22 is easier and cheaper to manufacture; (d) part 22 shields metal cover 23 and power electronics component 14 from oscillating magnetic fields reaching coil 15, thereby reducing eddy losses during charging; and (e) part 22 allows metal cover 23 to have a flat surface abutting non-conductive part 22, thereby preventing relative movement from causing excessive tension during thermal expansion.

[0074]

[0074] The metal cover 23 may be glued onto the non-conductive part 22, and this adhesive bond can counteract said relative motion when the system is heated or cooled. The cooling channels 24 are formed by recesses in the non-conductive part 22 closed by the abutting metal cover 23. The non-conductive part 22, especially made of plastic, has a relatively low thermal conductivity. However, the low thermal conductivity of the non-conductive part 22 is not a drawback, since most of the heat (or at least, the highest heat density) is generated on the side of the power electronics 14, and the heat generation in the magnetic area (15-18) is well distributed and not very significant. The direct contact between the coolant flowing through the cooling channels and the metal cover 23 ensures that the heat is efficiently removed from the electrical part 14. Optional geometric shapes machined into the metal cover 23, for example pins or fins recessed into the recesses, may further improve the heat dissipation.

[0075]

[0075] A further advantage of having two separate parts, one highly thermally conductive and the other not, that together form a cooling channel, is that the metal cover can also be used for further purposes. In other words, the component used as the metal cover can be "loaned" from a different part of the vehicle, such as the vehicle body or the housing of the HV battery.

[0076]

[0076] Figure 6 shows a schematic example of the latter. In this embodiment, a battery housing 25 houses the HV battery 26 and the power electronics 27 necessary to charge the HV battery 26 based on AC generated in the coil by wirelessly receiving an oscillating magnetic field from a transmitter of an external supply. These power electronics 27 correspond to the electrical components 14 to be cooled, as shown in Figure 5. The area where the magnetic material 28 is mounted on the battery housing 25 corresponds to the metal cover 23, as shown in Figure 5. The magnetic material 28 corresponds to the coil 15, the ferrite 16, the potting 17 and the coil cover 18.

[0077]

[0077] One advantage of the configuration depicted in Fig. 6 is that it is lighter, since at least one component can be omitted. A further benefit is that the wireless charger (or at least a part thereof) can be retrofitted onto vehicles that may not already have such features (if the electronic components 27 are pre-installed). Also, the induction of the coolant through the plastic part 22 may have the advantage that in case of a fire, the plastic part 22 can melt, thereby releasing the coolant to help extinguish the fire.

[0078]

[0078] In a further embodiment, as shown in Fig. 7, the wireless charger comprises a coolant inlet 29 and a coolant outlet 30, both machined or formed in the non-conductive part 22. If injection molding techniques are used to fabricate the non-conductive part 22, the formation of the coolant inlet 29 and the coolant outlet 30 is very easy and cheap to achieve. A coolant pump (not shown) can be connected to the coolant inlet 29 and the coolant outlet 30 and can be mounted, for example, next to the charger 13.

[0079] 8A and 8B show another embodiment in schematic cross-sectional and perspective views, respectively.

[0080]

[0080] The power transformer assembly 13 is configured to convert the electromagnetic force of the oscillating electromagnetic field into power of a current for charging the storage device or energizing the electric load. The power transformer assembly comprises a magnetic assembly MA for receiving the oscillating electromagnetic field and converting the oscillating electromagnetic field into an alternating current. The power transformer assembly also comprises an electronic assembly PE for receiving an alternating current AC and converting the alternating current AC into a current for charging the storage device or energizing the electric load. In addition, the power transformer assembly comprises heat dissipation means P1, P2 for dissipating heat generated by the magnetic assembly MA and the electronic assembly PE during their respective power conversion operations. The heat dissipation means P1, P2 are arranged between the magnetic assembly MA and the electronic assembly PE and are in thermal contact with the magnetic assembly MA and the electronic assembly PE. The heat dissipation means P1, P2 include a first part P1 in thermal contact with the magnetic assembly MA and a second part P2 in thermal contact with the electronic assembly PE. The first part P1 comprises a first material and / or has a first structure adapted to dissipate heat flow from the magnetic assembly MA, and the second part P2 comprises a second material different from the first material and / or has a second structure different from the first structure adapted to dissipate heat flow from the electronic assembly PE. Preferably, the first part P1 is made from a polymer material that is easily manufactured by molding, for example injection molding. Preferably, the second part P2 is made from a metallic material.

[0081] 9A and 9B show a further embodiment (fifth embodiment) diagrammatically in cross-section and perspective view, respectively.

[0082]

[0082] The power transformer assembly 13 shown in Figures 9A and 9B differs from the power transformer assembly shown in Figures 8A and 8B in that the heat dissipation means P1, P2, P3 includes a third part P3 arranged between the first part P1 and the magnetic assembly MA. Preferably, the first part P1 is made from a polymer material that is easily manufactured by molding, for example injection molding. Preferably, the second part P2 is made from a metallic material. Preferably, the third part P3 is made from a metallic material.

[0083]

[0083] An exemplary power transformer assembly 13 or wireless charger 4, 13 for charging a high voltage (HV) battery 26 of a vehicle 2 includes: a coil 15 configured to wirelessly receive an oscillating magnetic field from an external transmitter and thereby generate an alternating current (AC); _ A ferrite 16 disposed adjacent to the coil; a cooling channel 24 disposed adjacent to at least one of the ferrite and the coil, the cooling channel 24 configured to provide a flow of a coolant; _ an electrical and / or electronic component 14 configured to charge the HV battery based on AC; a metal cover 23 separating the coil and the ferrite from the electrical components, at least one of the electrical components being disposed adjacent to the metal cover; a non-conductive part 22 configured to at least partially define a cooling channel and separate the coil and the ferrite from the metal cover; Equipped with.

[0084]

[0084] The cooling channels 24 may be defined, at least in part, by recesses machined or formed in the non-conductive component 22.

[0085]

[0085] The cooling channel 24 may be formed by abutting the metal cover 23 against the non-conductive part 22 to close the recess.

[0086]

[0086] The cooling channel may be formed by a plate closing the recess by abutting the non-conductive part, the plate separating the non-conductive part from the metal cover.

[0087]

[0087] Cooling channels may be incorporated into non-conductive components.

[0088]

[0088] The metal cover 23 may be at least a part of a housing 25 for the HV battery 26.

[0089]

[0089] The metal cover may be provided with a structure for enlarging the heat sink, the structure being immersed in the cooling channel.

[0090] A coolant inlet 29 and a coolant outlet 30 may be provided, both machined or formed in the non-conductive part 22.

[0091]

[0091] A metal cover 23 may be glued onto the non-conductive part 22.

[0092]

[0092] The metal cover 23 may be flat, at least in the area adjacent the non-conductive parts 22.

[0093]

[0093] The non-conductive part 22 may be made of plastic.

[0094]

[0094] The coil 15 and the ferrite 16 may be combined in one potting 17.

[0095]

[0095] A wireless charger (4, 13) as described in claim 12, further comprising a coil cover (18) made of plastic, the potting (17) being embedded within the coil cover, and the coil cover being configured to be joined with a non-conductive part (22).

[0096]

[0096] The transformer assembly 13 or the wireless charger 4, 13 may be provided with a sealing lip by which the cooling channel is bounded or enclosed.

[0097]

[0097] The metal cover may be made of aluminum and may be configured to shield the vehicle from oscillating magnetic fields.

[0098]

[0098] Although the invention has been illustrated above in part with reference to certain preferred embodiments, it will be understood that numerous modifications and combinations of the various features of the embodiments can be made, all of which are within the scope of the appended claims.

Claims

1. 1. A power transformer assembly (13) for converting electromagnetic power of an oscillating electromagnetic field into electrical power of a current for charging an electrical storage device or energizing an electrical load, the power transformer assembly comprising: a magnetic assembly (MA) for receiving said oscillating electromagnetic field and converting said oscillating electromagnetic field into an alternating current (AC); an electronic assembly (PE) for receiving said alternating current (AC) and converting said alternating current (AC) into said electric current; Equipped with A power transformer assembly (13) comprising heat dissipation means (P1, P2; P1, P2, P3) for dissipating heat generated by the magnetic assembly (MA) and the electronic assembly (PE) during their respective power conversion operations, a) said heat dissipation means (P1, P2; P1, P2, P3) are arranged between said magnetic assembly (MA) and said electronic assembly (PE) and are in thermal contact with said magnetic assembly (MA) and said electronic assembly (PE); b) said heat dissipation means a first part (P1) in thermal contact with said magnetic assembly (MA); a second part (P2) in thermal contact with said electronic assembly (PE); Including, c) said first part (P1) comprises a first material and / or has a first structure adapted to dissipate heat flow from said magnetic assembly (MA); d) said second part (P2) comprises a second material different from said first material and / or has a second structure different from said first structure adapted to dissipate heat flow from said electronic assembly (PE); A power transformer assembly (13).

2. 2. The power transformer assembly (13) of claim 1, wherein the first component (P1) comprises a first material having a first thermal conductivity and the second component (P2) comprises a second material having a second thermal conductivity, the second thermal conductivity being greater than the first thermal conductivity.

3. 3. The power transformer assembly (13) of claim 1 or 2, wherein the second material has a thermal conductivity greater than 100 W / (m·K).

4. The power transformer assembly (13) of any one of claims 1 to 3, wherein the first material and / or the second material is a metal, a metal alloy, a polymer, a polymer blend, or a composite material.

5. The power transformer assembly (13) of any one of claims 1 to 4, wherein the first material is a polymer or a polymer blend.

6. The power transformer assembly (13) of any one of claims 1 to 5, wherein the second material is a metal, a metal alloy, or a composite material.

7. A power transformer assembly (13) according to any one of the preceding claims, wherein said first part (P1) comprises a portion defining a duct for a heat transfer fluid (coolant).

8. 8. A power transformer assembly (13) according to claim 7, wherein the first part (P1) having the portion defining the duct is made by forming (shaping) a material in a mould.

9. 9. The power transformer assembly (13) of claim 8, wherein the first part (P1) having a portion defining the duct is made by molding (casting, injecting) a moldable material in the mold.

10. 9. A power transformer assembly (13) according to claim 8, wherein said first part (P1) having a portion defining said duct is made by sintering a sinterable material in said mould.

11. 9. The power transformer assembly (13) of claim 8, wherein the first part (P1) having a portion defining the duct is made by crosslinking a crosslinkable material in the mold.

12. 8. The power transformer assembly (13) of claim 7, wherein the first part (P1) having the portion defining the duct is fabricated additively layer by layer.

13. A power transformer assembly (13) according to any one of claims 7 to 12, wherein the first part (P1) comprises a polymer.

14. 14. The power transformer assembly (13) of claim 13, wherein the first part (P1) comprises a polymer matrix having particles dispersed therein, the particles being selected from the group comprising metal particles and graphite particles.

15. A power transformer assembly (13) according to any one of the preceding claims, wherein the second part (P2) comprises a solid metallic material.

16. A power transformer assembly (13) according to any one of the preceding claims, wherein the second part (P2) comprises a porous metallic material.

17. A power transformer assembly (13) according to any one of the preceding claims, wherein the second part (P2) comprises a metal layer.

18. A power transformer assembly (13) according to any one of the preceding claims, wherein the magnetic assembly (MA) comprises a coil (15).

19. 20. The power transformer assembly (13) of claim 18, wherein the magnetic assembly (MA) comprises a material (16) adjacent the coil (15), the material (16) having a magnetic permeability of at least 1.

20. 20. The power transformer assembly (13) of claim 19, wherein the material (16) adjacent the coil (15) is ferrite.

21. A power transformer assembly (13) according to any one of the preceding claims, wherein the electronic assembly (PE) comprises power electronic components.

22. 22. A power transformer assembly (13) according to any one of the preceding claims, wherein the heat dissipation means (P1, P2; P1, P2, P3) comprises a third part (P3) arranged between the first part (P1) and the magnetic assembly (MA).

23. 23. The power transformer assembly (13) of claim 22, wherein the third part (P3) comprises a solid metallic material.

24. 24. A power transformer assembly (13) according to claim 22 or 23, wherein the third part (P3) comprises a porous metallic material.

25. A power transformer assembly (13) according to any one of claims 22 to 24, wherein the third part (P3) comprises a metal layer.

26. 26. A power transformer assembly (13) according to any one of claims 22 to 25, wherein a three-component sandwich arrangement (P1, P2, P3) consisting of the first component (P1), the second component (P2) and the third component (P3) is arranged between the magnetic assembly (MA) and the electronic assembly (PE) and is in thermal contact with each of the magnetic assembly (MA) and the electronic assembly (PE).

27. 27. The power transformer assembly (13) of any one of claims 7 to 26, wherein the duct (24) for the heat transfer fluid defined by the material of the first part (P1) comprises a plurality of flow obstacles extending across the duct (24).

28. 28. The power transformer assembly (13) of claim 27, wherein at least a portion of said flow obstructions are integrally formed with said first part (P1).

29. 30. A power transformer assembly (13) according to claim 27 or 28, wherein at least some of the flow obstructions are integrally formed with the second part (P2).

30. A power transformer assembly (13) according to any one of claims 27 to 29, wherein at least some of said flow obstructions are integrally or monolithically formed with said third part (P3).

31. A power transformer assembly (13) according to any one of claims 7 to 30, wherein the first part (P1) comprises functional parts (29, 30) integrally formed with a duct-defining material of the first part (P1).

32. 32. The power transformer assembly (13) of claim 31, wherein the functional portions include at least one of a heat transfer fluid (coolant) inlet (29), a heat transfer fluid (coolant) outlet (30), a snorkel (breathing element), and an interface structure.

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