Power transformer assembly
The power transformer assembly addresses manufacturing challenges by using a modular heat dissipation system with tailored materials and structures for magnetic and electronic components, enhancing efficiency and reducing costs through optimized heat transfer and mechanical strength.
Patent Information
- Authority / Receiving Office
- JP · JP
- Patent Type
- Applications
- Current Assignee / Owner
- BRUSA ELEKTRONIK AG
- Filing Date
- 2026-03-09
- Publication Date
- 2026-07-07
Smart Images
Figure 2026113492000001_ABST
Abstract
Description
Technical Field
[0001]
[0001] The present invention relates to a power transformer assembly for converting the electromagnetic force of an oscillating electromagnetic field into the power of a current or an available current for charging a power storage device or energizing an electrical load. The power transformer assembly includes 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 a current or an available current. The power transformer assembly further includes heat dissipation means for dissipating heat generated by the electronic assembly during their respective power conversion operations.
[0002]
[0002] The power transformer assembly, also referred to as 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), receives an oscillating magnetic field from an external transmitter, sometimes called a ground pad module (GPM), and can convert the oscillating electromagnetic, mainly magnetic, field into an alternating current, which is converted (typically rectified) into a current (typically direct current) used to charge the HV battery.
Background Art
[0003]
[0003] The batteries of electric vehicles can be charged using alternating current (AC) or direct current (DC) energy transfer. DC energy transfer is typically performed using a high-power converter placed at a dedicated charging point. DC charging is typically faster than AC charging, but due to the high cost of installing DC charging points and the typically fragile existing network capacity in residential areas, DC charging points are typically placed in remote locations and not installed in or near residential areas, making them inconvenient for end-users.
[0004]
[0004] On the other hand, AC charging is very important for residential and (semi-)public urban areas. A typical AC charger can supply up to 22 kW of charging power. AC charging systems can be divided into wired charging systems and wireless charging systems, with wireless charging systems being mainly embodied as inductive charging systems (ICS). Wired AC chargers are typically built into electric vehicles and are also called on-board chargers. An ICS typically consists of two separate modules, often called a ground pad module (GPM) and a car pad module (CPM).
[0005]
[0005] The GPM is installed on the outside of the electric vehicle, while the CPM is installed inside the electric vehicle, usually on the underside of the vehicle. The electromagnetic interaction between the GPM and the CPM enables energy transfer from the GPM to the CPM, which is then used to charge the electric vehicle's battery. Wireless charging systems are often more convenient for the user because they typically do not require manual intervention to start the battery charging process other than parking the vehicle above the GPM. Wired charging systems, on the other hand, require the user 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 unit" or simply "supply unit" 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. In addition, the terms "power transformer assembly" and "wireless charger" or "wireless charger module" are used interchangeably in this document.
[0007]
[0007] With regard to cooling, it is important to understand that a CPM has two heat-generating regions: (a) electronic assemblies (power electronics) that generate a large amount of heat, but relatively concentrated in specific locations (high density), and (b) magnetic assemblies (coils and ferrites) that generate less heat, but relatively well distributed (low density). Prior art cooling systems for such CPMs are not adequately adapted to these circumstances and are relatively difficult to manufacture, and therefore expensive. Object of the Invention
[0008]
[0008] Therefore, an object of the present invention is to provide a power transformer assembly that can be easily manufactured at a relatively low cost and that satisfies the overall cooling requirements, particularly the cooling requirements of the electronic assembly. [Overview of the project]
[0009]
[0009] The purpose is a power transformer assembly for converting the electromagnetic force of an oscillating electromagnetic field into electric current for charging a power storage device or supplying power to an electrical load, wherein the power transformer assembly A magnetic assembly that receives an oscillating electromagnetic field and converts the oscillating electromagnetic field into an alternating current, An electronic assembly for receiving alternating current and converting alternating current into electric current, Equipped with, In a power transformer assembly comprising heat dissipation means for dissipating heat generated by the magnetic assembly and the electronic assembly during the power conversion operation of the magnetic assembly and the electronic assembly, respectively, _a) A heat dissipation means is positioned between the magnetic assembly and the electronic assembly, and is in thermal contact with the magnetic assembly and the electronic assembly, _b) Heat dissipation means, _A first component that is in thermal contact with the magnetic assembly, _A second component that is in thermal contact with the electronic assembly, Includes, _c) The first component comprises a first material and / or has a first structure adapted to dissipate heat flow from the magnetic assembly, _d) The second component comprises a second material different from the first material and / or has a second structure different from the first structure, which is adapted to dissipate heat flow from the electronic assembly. This is achieved by a power transformer assembly characterized by the following features.
[0010]
[0010] As a result, a first component comprising a first material and / or a first structure that is in thermal contact with the magnetic assembly and adapted to dissipate heat flow from the magnetic assembly provides a first part for overall heat dissipation from the power transformer assembly. Similarly, a second component comprising a second material different from the first material and / or having a second structure different from the first structure that is in thermal contact with the electronic assembly provides a second part for overall heat dissipation from the power transformer assembly. In other words, in a power transformer assembly, where the magnetic assembly is a first type of heat source and the electronic assembly is a second type of heat source, the present invention enables heat dissipation specific to the heat source 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 structure of the first component (first type of heat sink) and the second component (second type of heat sink) to differ from each other, each of the first and second components must satisfy the heat dissipation requirements of the magnetic assembly (first type of heat source) and the electronic assembly (second type of heat source), respectively. Therefore, the first component may be provided with a first material and a first structure that primarily satisfies 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 satisfies only the heat dissipation requirements of the electronic assembly. Thus, the specific heat dissipation requirements for each of the first and second components can be minimal, thereby enabling significant savings. For example, savings can be achieved by selecting a material with low thermal conductivity, and low thermal conductivity may be compensated for by providing this material with a special structure that helps improve heat flow. Furthermore, this invention increases the design flexibility of power transformers and facilitates the reduction of related components.
[0011]
[0011] Preferably, the first component comprises a first material having a first thermal conductivity, and the second component comprises a second material having a second thermal conductivity, wherein the second thermal conductivity is greater than the first thermal conductivity.
[0012]
[0012] Preferably, the thermal conductivity of the second material is greater than 100 W / (m·K). This ensures sufficient heat flow from the electronic assembly as a heat source with 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]
[0016] In a preferred embodiment, the first component includes a portion defining a duct for a heat transfer fluid (coolant). This allows the first component to be positioned in fluid connection with the coolant circuit, and the duct of the first component is preferably part of the coolant circuit.
[0017]
[0017] Preferably, the first component having the portion defining the duct is manufactured by forming (shaping) the material in a mold. This makes it possible to reduce manufacturing costs.
[0018]
[0018] The first component having the portion defining the duct may be manufactured by molding (casting, injection molding) a material that can be molded in the mold.
[0019]
[0019] The first component having a portion defining the duct may be manufactured by sintering a sinterable material in the mold.
[0020]
[0020] The first component having the portion defining the duct may be manufactured by crosslinking a crosslinkable material in the mold.
[0021]
[0021] Preferably, the first component having the portion defining the duct is fabricated layer by layer. This allows for complex geometric shapes for fabricating the first component, which helps in efficient heat transfer from the magnetic assembly (coils, ferrite) as a more uniformly distributed heat source to the first component as a heat sink having a heat transfer fluid (coolant) flowing through the duct.
[0022]
[0022] Preferably, the first component includes a polymer. This makes it possible to manufacture the first component having a duct geometric shape by molding at low cost.
[0023]
[0023] The first component may include a polymer matrix in which particles are dispersed, and the particles are selected from the group including metal particles and graphite particles. These particles enhance the conductivity of the polymer.
[0024]
[0024] Preferably, the second component includes a solid metal material. This ensures sufficient heat flow from the electronic assembly as a heat source having concentrated hot spots and a relatively high temperature. In addition, the second component provides additional mechanical strength against the overall dissipation means.
[0025]
[0025] Preferably, the second component includes a porous metal material. This 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. _Thus, weight reduction and material cost reduction with respect to the solid metal material can be achieved.
[0026]
[0026] In a preferred embodiment, the second component includes a metal layer. This metal layer contributes to the homogenization of local temperature peaks / hot spots of 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 to the coil, and the material has a permeability of 1 or more.
[0029]
[0029] Preferably, the material adjacent to the coil is ferrite.
[0030]
[0030] Preferably, the electronic assembly comprises power electronics components.
[0031]
[0031] Preferably, the heat dissipation means includes a third component positioned between the first component and the magnetic assembly. As previously stated, the first component may be provided with a first material and a first structure that primarily satisfies 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 satisfies only the heat dissipation requirements of the electronic assembly. The third component can 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 geometric shape. Therefore, the overall heat dissipation means for a 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 the mechanical properties of the overall heat dissipation means.
[0032]
[0032] Preferably, the third component includes a solid metal material. This ensures sufficient heat flow from the magnetic assembly. Again, the third component provides additional mechanical strength to the overall dissipation means.
[0033]
[0033] Preferably, the third component includes a porous metal material. Again, this makes it possible to reduce the amount of metal material required without any significant decrease in the thermal conductivity and mechanical strength of the third component. Thus, it is possible to reduce weight and material costs compared to solid metal materials.
[0034]
[0034] Preferably, the third component includes a metal layer. Again, this metal layer contributes to homogenizing local temperature non-uniformity of the magnetic assembly by transverse heat flow along the metal layer.
[0035]
[0035] Preferably, the sandwich configuration of three parts, consisting of a first part, a second part, and a third part, is positioned between the magnetic assembly and the electronic assembly and is in thermal contact with each of the magnetic assembly and the electronic assembly. The sandwich configuration of three parts, consisting of the first, second, and third parts as defined above, helps to improve the mechanical strength of this sandwich-type overall heat dissipation means. Preferably, this sandwich structure is positioned 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 components have higher mechanical strength than the first component between the two components, the second and third components. This provides an overall heat dissipation means with high bending stiffness. Preferably, the second and third components are made from solid or porous metal layers, while the first component in between may be made from a polymer. The first component may be a web structure, preferably a perforated honeycomb structure, which allows coolant flow while providing high bending stiffness with minimal weight.
[0036]
[0036] Preferably, the duct for the heat transfer fluid, defined by the material of the first component, comprises a plurality of flow obstructions extending across the duct.
[0037]
[0037] At least a portion of the flow obstruction may be formed integrally with the first component.
[0038]
[0038] At least a portion of the flow obstruction may be formed integrally with the second component.
[0039]
[0039] At least a portion of the flow obstruction may be formed integrally with the third component.
[0040]
[0040] Preferably, the first component includes a functional portion formed integrally with the duct defining material of the first component.
[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 vehicle high-voltage (HV) battery, comprising: a coil configured to wirelessly receive an oscillating magnetic field from an external transmitter and thereby generate an alternating current; a ferrite positioned adjacent to the coil; a cooling channel positioned adjacent to at least one of the ferrite and the coil, wherein the cooling channel is configured to provide a flow of coolant; an electrical component configured to charge the HV battery based on AC; and a metal cover separating the coil and the ferrite from the electrical component, wherein at least one of the electrical component is positioned adjacent to the metal cover, wherein the wireless charger further comprises a non-conductive component configured to at least partially form a cooling channel and separate the coil and the ferrite from the metal cover.
[0043]
[0043] In some embodiments, the cooling channel is at least partially formed by a recess that is machined or formed within a non-conductive component.
[0044]
[0044] In some embodiments, the cooling channel is formed by closing a recess when a metal cover abuts against a non-conductive component.
[0045]
[0045] In some embodiments, the wireless charger further comprises a plate, the cooling channel being formed by the plate closing a recess by contacting a non-conductive component, the plate separating the non-conductive component from the metal cover.
[0046]
[0046] In some embodiments, the cooling channel is incorporated into a non-conductive component.
[0047]
[0047] In some embodiments, the metal cover is at least part of the housing of the HV battery.
[0048]
[0048] In some embodiments, the metal cover includes a structure for expanding the heat sink, and the structure is 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 within a non-conductive component.
[0050]
[0050] In some embodiments, the metal cover is bonded to the non-conductive component.
[0051]
[0051] In some embodiments, the metal cover is flat in at least the area adjacent to the non-conductive component.
[0052]
[0052] In some embodiments, the non-conductive component is made of plastic.
[0053]
[0053] In some embodiments, the coil and ferrite are combined within a single 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 bond with a non-conductive component.
[0055]
[0055] In some embodiments, the wireless charger further comprises a seal lip which is bounded or surrounded by a cooling channel.
[0056]
[0056] In some embodiments, the metal cover is made of aluminum and is configured to shield the vehicle from the vibrating magnetic field. [Brief explanation of the drawing]
[0057]
[0057] As merely an example, preferred embodiments of the present invention will be fully described below with reference to the accompanying drawings.
[0058] [Figure 1]
[0058] Figure 1 is a top view of a garage in which a vehicle is parked above a wireless charging supply unit located outside the vehicle and having a transmitter for transmitting vibration magnetic fields.
[0059] [Figure 2]
[0059] Figure 2 is an enlarged view of Figure 1 and shows a wireless charging supply unit and wireless charger for charging the vehicle's high-voltage (HV) battery.
[0060] [Figure 3]
[0060] Figure 3 shows the charger from Figure 2 in an enlarged 3D view.
[0061] [Figure 4]
[0061] Figure 4 shows a cross-sectional view of a charger according to the prior art.
[0062] [Figure 5]
[0062] Figure 5 shows an exemplary embodiment (first embodiment) of the charger of the present invention.
[0063] [Figure 6]
[0063] Figure 6 schematically shows a further embodiment (second embodiment) in which the metal cover is "provided" by the housing of the HV battery.
[0064] [Figure 7]
[0064] Figure 7 shows an exemplary embodiment (third embodiment) of a wireless charger, which includes a coolant inlet and coolant outlet that are machined or formed inside a non-conductive component.
[0065] [Figure 8A]
[0065] Figure 8A schematically shows another embodiment (the fourth embodiment) as a cross-sectional view. [Figure 8B]
[0065] Figure 8B schematically shows another embodiment (the fourth embodiment) as a perspective view.
[0066] [Figure 9A]
[0066] Figure 9A schematically shows a further embodiment (the fifth embodiment) as a cross-sectional view. [Figure 9B]
[0066] Figure 9B schematically shows a further embodiment (the fifth embodiment) as a perspective view. [Modes for carrying out the invention]
[0067]
[0067] Figure 1 shows a top view of garage 1, in which vehicle 2 is parked on a wireless charging supply unit 3 located outside vehicle 2 and having a transmitter for transmitting vibration magnetic fields. The supply unit 3 can be seen as vehicle 2 is depicted as transparent. Such a charging solution is very convenient and eliminates the need for the driver to plug and unplug charging cables.
[0068]
[0068] Figure 2 is an enlarged view of Figure 1, and further shows the wireless charging supply unit 3 and a wireless charger 4 for charging the vehicle's high-voltage (HV) battery, which is "floating" above the supply unit 3. The charger 4 is mounted on the vehicle, which means that the rest of the vehicle is hidden in this figure.
[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 unit 3. The oscillating magnetic field induces alternating current (AC) in the coil. A ferrite 7 is positioned adjacent to the coil 6. A cooling channel 8 is positioned adjacent to the ferrite 7 and is configured to provide a flow of coolant. The flowing coolant cools a metal cover 9 into which the cooling channel is incorporated. An electrical component 10 configured to charge the HV battery based on AC is positioned adjacent to the metal cover for heat dissipation. The metal cover 9 isolates the coil 6 and ferrite 7 from the electrical component 10. The coil 6 and ferrite 7 are embedded in potting 11, which is protected by a coil cover 12. The potting 11 and coil cover 12 are typically made of plastic.
[0071]
[0071] A drawback of the configuration described in Figure 4 is that the arrangement of the coils / ferrites 6 / 7 is very close to the metal cover 9 and is not insulated from the metal cover 9, resulting in relatively high eddy current losses. More specifically, the configuration shown in Figure 4 causes very complex deformation due to thermal expansion because the metal cover 9 is hooked into the magnetic assembly 11 / 12, which, as a plastic component, has a considerably different coefficient of thermal expansion than the metal cover 9. These relative motions can cause material fatigue over time. Furthermore, the complex geometric shape of the metal cover 9 is difficult and expensive to achieve.
[0072]
[0072] Despite the differences described in Figure 5, the wireless charger according to the present invention has the components described above in Figure 4. One or more related electrical components 10 (or 14 in Figure 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 enables control of the charging process, in particular control of the DC / DC converter. Another optional component is a sensor (not shown) which may be used to determine the position of the charger 13 relative to a power supply unit (indicated by reference numeral 3 in Figures 1 and 2) on which a vehicle is parked.
[0073]
[0073] Figure 5 shows an exemplary embodiment of the charger of the present invention. The coil 15 and 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 configured to receive lugs 21 belonging to a non-conductive component 22. The non-conductive component 22 may be manufactured from, for example, plastic, particularly by injection molding. The advantages of this component 22 include (a) that component 22 is in direct contact with the potting 20 having a similar coefficient of thermal expansion, and therefore causes little to no relative motion between the two components due to thermal expansion; (b) that component 22 is lighter than components known from chargers of the prior art; (c) that component 22 is easier and less expensive to manufacture; (d) that component 22 shields the metal cover 23 and power electronics components 14 from oscillating magnetic fields reaching the coil 15, thereby reducing vortex losses during charging; and (e) that component 22 allows the metal cover 23 to have a flat surface in contact with the non-conductive component 22, thereby preventing relative motion during thermal expansion from causing excessive tension.
[0074]
[0074] The metal cover 23 may be bonded to the non-conductive component 22, and this adhesive bond can absorb the relative motion when the system is being heated or cooled. The cooling channels 24 are formed by recesses in the non-conductive component 22 that are closed by the abutting metal cover 23. Non-conductive components 22 made of plastic in particular have relatively low thermal conductivity. However, the low thermal conductivity of the non-conductive component 22 is not a disadvantage, as most of the heat (or at least the highest thermal density) is generated on the side of the power electronics 14, and the heat generation in the magnetic areas (15-18) is well distributed and not so significant. Direct contact between the coolant flowing through the cooling channels and the metal cover 23 ensures that heat is efficiently removed from the electrical components 14. Optional geometric shapes machined within the metal cover 23, such as pins or fins embedded in recesses, may further improve heat dissipation.
[0075]
[0075] A further advantage of having two separate parts, one with high thermal conductivity and the other with low thermal conductivity, which jointly 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 "borrowed" from different parts of the vehicle, such as the vehicle body or the housing of the HV battery.
[0076]
[0076] Figure 6 schematically illustrates the latter example. In this embodiment, the 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 an external power supply transmitter. These power electronics 27 correspond to the electrical components 14 to be cooled, as shown in Figure 5. The area on the battery housing 25 to which the magnetic material 28 is mounted corresponds to the metal cover 23, as shown in Figure 5. The magnetic material 28 corresponds to the coil 15, ferrite 16, potting 17, and coil cover 18.
[0077]
[0077] One advantage of the configuration shown in Figure 6 is that it is lighter because at least one component can be omitted. A further advantage is that the wireless charger (or at least a part thereof) can be retrofitted onto a vehicle that does not yet have such a feature (provided that the electronic component 27 is pre-installed). Also, the induction of the coolant through the plastic component 22 may have the advantage that in the event of a fire, the plastic component 22 may melt, thereby releasing the coolant and helping to extinguish the fire.
[0078]
[0078] In a further embodiment, as shown in Figure 7, the wireless charger includes a coolant inlet 29 and a coolant outlet 30, both machined or formed within a non-conductive component 22. If injection molding technology is used to manufacture the non-conductive component 22, the formation of the coolant inlet 29 and coolant outlet 30 can be achieved very easily and inexpensively. A coolant pump (not shown) may be connected to the coolant inlet 29 and coolant outlet 30 and can be mounted, for example, next to the charger 13.
[0079]
[0079] Figures 8A and 8B schematically show another embodiment as a cross-sectional view and a perspective view, respectively.
[0080]
[0080] The power transformer assembly 13 is configured to convert the electromagnetic force of an oscillating electromagnetic field into power in the form of an electric current for charging the energy storage device or energizing an electrical load. The power transformer assembly includes 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 includes an electronic assembly PE for receiving an alternating current AC and converting the alternating current AC into an electric current for charging the energy storage device or energizing an electrical load. In addition, the power transformer assembly includes heat dissipation means P1, P2 for dissipating the heat generated by the magnetic assembly MA and the electronic assembly PE during their respective power conversion operations. The heat dissipation means P1 and P2 are positioned 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 and P2 include a first component P1 that is in thermal contact with the magnetic assembly MA and a second component P2 that is in thermal contact with the electronic assembly PE. The first component P1 comprises a first material and / or has a first structure adapted to dissipate heat flow from the magnetic assembly MA. The second component 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 component P1 is made from a polymer material that is easily manufactured by molding, for example, injection molding. Preferably, the second component P2 is made from a metal material.
[0081]
[0081] Figures 9A and 9B schematically show a further embodiment (a fifth embodiment) as a cross-sectional view and a 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, and P3 include a third component P3 positioned between the first component P1 and the magnetic assembly MA. Preferably, the first component P1 is made from a polymer material that is easily manufactured by molding, for example, injection molding. Preferably, the second component P2 is made from a metal material. Preferably, the third component P3 is made from a metallic material.
[0083]
[0083] An exemplary power transformer assembly 13 or wireless charger 4, 13 for charging the high-voltage (HV) battery 26 of the vehicle 2 is provided. A coil 15 is configured to wirelessly receive an oscillating magnetic field from an external transmitter and generate alternating current (AC) thereafter. A ferrite 16 is positioned adjacent to the coil, A cooling channel 24 is positioned adjacent to at least one of the ferrite and the coil, and the cooling channel is configured to provide a flow of coolant, Electrical and / or electronic components 14 configured to charge the HV battery based on AC, A metal cover 23 that separates a coil and ferrite from electrical components, wherein at least one of the electrical components is located adjacent to the metal cover 23, A non-conductive component 22 is configured to at least partially form a cooling channel and to separate the coil and ferrite from the metal cover, It is equipped with.
[0084]
[0084] The cooling channel 24 may be at least partially formed by a recess that is machined or formed within the nonconductive component 22.
[0085]
[0085] The cooling channel 24 may be formed by the metal cover 23 closing a recess by contacting the non-conductive component 22.
[0086]
[0086] The cooling channel may be formed by a plate that closes a recess by contacting a non-conductive component, the plate separating the non-conductive component from the metal cover.
[0087]
[0087] The cooling channel may be incorporated into a non-conductive component.
[0088]
[0088] The metal cover 23 may be at least part of the housing 25 of the HV battery 26.
[0089]
[0089] The metal cover may have a structure for expanding the heat sink, the structure being immersed in the cooling channel.
[0090]
[0090] A coolant inlet 29 and a coolant outlet 30 may be provided, and both the coolant inlet and the coolant outlet are machined or formed within the non-conductive component 22.
[0091]
[0091] The metal cover 23 may be bonded to the non-conductive component 22.
[0092]
[0092] The metal cover 23 may be flat in at least the area adjacent to the non-conductive component 22.
[0093]
[0093] The non-conductive component 22 may be made of plastic.
[0094]
[0094] The coil 15 and the ferrite 16 may be combined within a single potting 17.
[0095]
[0095] The wireless charger (4, 13) according to claim 12, further comprising a coil cover (18) made of plastic, wherein the potting (17) is embedded within the coil cover, and the coil cover is configured to be joined with a non-conductive component (22).
[0096]
[0096] The transformer assembly 13 or wireless charger 4, 13 may have a sealing lip which is bounding or surrounding the cooling channel.
[0097]
[0097] The metal cover may be made of aluminum and may be configured to shield the vehicle from vibrational magnetic fields.
[0098]
[0098] Although the present invention has been illustrated above with reference to some preferred embodiments in part, it should be understood that numerous modifications and combinations of various features of the embodiments are possible. All of these modifications are within the scope of the appended claims. [Item of the invention] [Item 1] A power transformer assembly (13) for converting the electromagnetic force of an oscillating electromagnetic field into electric power for charging a power storage device or supplying power to an electrical load, wherein the power transformer assembly is A magnetic assembly (MA) that receives the aforementioned vibrating electromagnetic field and converts the aforementioned vibrating electromagnetic field into alternating current (AC), An electronic assembly (PE) that receives the alternating current (AC) and converts the alternating current (AC) into the current, Equipped with, In the power transformer assembly (13), the power transformer assembly (13) is provided with heat dissipation means (P1, P2; P1, P2, P3) for dissipating the heat generated by the magnetic assembly (MA) and the electronic assembly (PE) during their respective power conversion operations, a) The heat dissipation means (P1, P2; P1, P2, P3) is positioned between the magnetic assembly (MA) and the electronic assembly (PE), and is in thermal contact with the magnetic assembly (MA) and the electronic assembly (PE), b) The heat dissipation means, A first component (P1) that is in thermal contact with the magnetic assembly (MA), A second component (P2) that is in thermal contact with the aforementioned electronic assembly (PE), Includes, c) The first component (P1) comprises a first material and / or has a first structure adapted to dissipate heat flow from the magnetic assembly (MA), d) The second component (P2) comprises a second material different from the first material and / or has a second structure different from the first structure, which is adapted to dissipate heat flow from the electronic assembly (PE). A power transformer assembly (13) characterized by the following: [Item 2] The power transformer assembly (13) according to item 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. [Item 3] A power transformer assembly (13) according to item 1 or 2, wherein the thermal conductivity of the second material is greater than 100 W / (m·K). [Item 4] A power transformer assembly (13) according to any one of items 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. [Item 5] A power transformer assembly (13) according to any one of items 1 to 4, wherein the first material is a polymer or a polymer blend. [Item 6] A power transformer assembly (13) according to any one of items 1 to 5, wherein the second material is a metal, a metal alloy, or a composite material. [Item 7] A power transformer assembly (13) according to any one of items 1 to 6, wherein the first component (P1) comprises a portion defining a duct for a heat transfer fluid (coolant). [Item 8] The power transformer assembly (13) according to item 7, wherein the first component (P1) having a portion defining the duct is manufactured by forming (shaping) the material in a mold. [Item 9] The power transformer assembly (13) according to item 8, wherein the first component (P1) having a portion defining the duct is manufactured by molding (casting, injection molding) a material that can be molded in the mold. [Item 10] The power transformer assembly (13) according to item 8, wherein the first component (P1) having a portion defining the duct is manufactured by sintering a sinterable material in the mold. [Item 11] The power transformer assembly (13) according to item 8, wherein the first component (P1) having a portion defining the duct is manufactured by crosslinking a crosslinkable material in the mold. [Item 12] The power transformer assembly (13) according to item 7, wherein the first component (P1) having a portion defining the duct is additionally manufactured layer by layer. [Item 13] The first component (P1) comprises a polymer, the power transformer assembly (13) as described in any one of items 7 to 12. [Item 14] The power transformer assembly (13) according to item 13, wherein the first component (P1) comprises a polymer matrix in which particles are dispersed, and the particles are selected from the group comprising metal particles and graphite particles. [Item 15] The power transformer assembly (13) described in any one of items 1 to 14, wherein the second component (P2) comprises a solid metal material. [Item 16] The power transformer assembly (13) according to any one of items 1 to 15, wherein the second component (P2) comprises a porous metal material. [Item 17] The power transformer assembly (13) described in any one of items 1 to 16, wherein the second component (P2) includes a metal layer. [Item 18] A power transformer assembly (13) according to any one of items 1 to 17, wherein the magnetic assembly (MA) comprises a coil (15). [Item 19] The power transformer assembly (13) according to item 18, wherein the magnetic assembly (MA) comprises a material (16) adjacent to the coil (15), and the material (16) has a permeability of 1 or more. [Item 20] The power transformer assembly (13) according to item 19, wherein the material (16) adjacent to the coil (15) is ferrite. [Item 21] A power transformer assembly (13) according to any one of items 1 to 20, wherein the electronic assembly (PE) comprises power electronics components. [Item 22] A power transformer assembly (13) according to any one of items 1 to 21, wherein the heat dissipation means (P1, P2; P1, P2, P3) includes a third component (P3) positioned between the first component (P1) and the magnetic assembly (MA). [Item 23] The third component (P3) is a power transformer assembly (13) as described in item 22, comprising a solid metal material. [Item 24] The power transformer assembly (13) according to item 22 or 23, wherein the third component (P3) comprises a porous metal material. [Item 25] The third component (P3) is a power transformer assembly (13) as described in any one of items 22 to 24, wherein the third component (P3) includes a metal layer. [Item 26] A power transformer assembly (13) according to any one of items 22 to 25, wherein a sandwich configuration of three components (P1, P2, P3) consisting of a first component (P1), a second component (P2), and a third component (P3) is positioned 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). [Item 27] A power transformer assembly (13) according to any one of items 7 to 26, wherein the duct (24) for the heat transfer fluid, defined by the material of the first component (P1), comprises a plurality of flow obstructions extending across the duct (24). [Item 28] The power transformer assembly (13) according to item 27, wherein at least a portion of the flow obstruction is integrally formed with the first component (P1). [Item 29] A power transformer assembly (13) according to item 27 or 28, wherein at least a portion of the flow obstruction is integrally formed with the second component (P2). [Item 30] A power transformer assembly (13) according to any one of items 27 to 29, wherein at least a portion of the flow obstruction is formed integrally or monolithically with the third component (P3). [Item 31] A power transformer assembly (13) according to any one of items 7 to 30, wherein the first component (P1) comprises functional parts (29, 30) integrally formed with the duct defining material of the first component (P1). [Item 32] The power transformer assembly (13) according to item 31, wherein the functional part includes 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.
Claims
1. A power transformer assembly (13) for converting the electromagnetic force of an oscillating electromagnetic field into electric power for charging a power storage device or supplying power to an electrical load, wherein the power transformer assembly is A magnetic assembly (MA) that receives the aforementioned vibrating electromagnetic field and converts the aforementioned vibrating electromagnetic field into alternating current (AC), An electronic assembly (PE) for receiving the alternating current (AC) and converting the alternating current (AC) into the current, Equipped with, The power transformer assembly (13) includes 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) The heat dissipation means (P1, P2; P1, P2, P3) is positioned between the magnetic assembly (MA) and the electronic assembly (PE), and is in thermal contact with the magnetic assembly (MA) and the electronic assembly (PE), b) The heat dissipation means is A first component (P1) that is in thermal contact with the magnetic assembly (MA), A second component (P2) that is in thermal contact with the aforementioned electronic assembly (PE), Includes, c) The first component (P1) comprises a first material and has a first structure adapted to dissipate heat flow from the magnetic assembly (MA), d) In a power transformer assembly (13) in which the second component (P2) comprises a second material different from the first material and has a second structure different from the first structure, which is adapted to dissipate heat flow from the electronic assembly (PE), The second component (P2) includes a metal layer, The first material is a polymer or polymer blend, The first component (P1) has a portion that defines a plurality of recesses that are machined or formed in the first component (P1), and a plurality of ducts for heat transfer fluid are formed when the second component (P2) abuts against the first component (P1) to close the recesses. A power transformer assembly (13) characterized by the following features.
2. The power transformer assembly (13) according to 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, wherein the second thermal conductivity is greater than the first thermal conductivity.
3. The power transformer assembly (13) according to claim 1, wherein the thermal conductivity of the second material is greater than 100 W / (m·K).
4. The power transformer assembly (13) according to claim 1, wherein the second material is a metal, a metal alloy, or a composite material.
5. The power transformer assembly (13) according to any one of claims 1 to 4, wherein the first component (P1) having a portion defining the duct is manufactured by molding (casting, injection molding) a material that can be molded in a mold.
6. The power transformer assembly (13) according to any one of claims 1 to 4, wherein the first component (P1) having a portion defining the duct is manufactured by sintering a sinterable material in a mold.
7. The power transformer assembly (13) according to claim 5, wherein the first component (P1) having a portion defining the duct is manufactured by crosslinking a crosslinkable material in the mold.
8. The power transformer assembly (13) according to any one of claims 1 to 4, wherein the first component (P1) having a portion defining the duct is additionally manufactured layer by layer.
9. The power transformer assembly (13) according to any one of claims 1 to 4, wherein the first component (P1) comprises a polymer matrix in which particles are dispersed, and the particles are selected from the group comprising metal particles and graphite particles.
10. The power transformer assembly (13) according to claim 1, wherein the second component (P2) comprises a solid metal material.
11. The power transformer assembly (13) according to claim 1, wherein the second component (P2) comprises a porous metal material.
12. The power transformer assembly (13) according to claim 1, wherein the magnetic assembly (MA) comprises a coil (15).
13. The power transformer assembly (13) according to claim 12, wherein the magnetic assembly (MA) comprises a material (16) adjacent to the coil (15), and the material (16) has a magnetic permeability of 1 or more.
14. The power transformer assembly (13) according to claim 13, wherein the material (16) adjacent to the coil (15) is ferrite.
15. The power transformer assembly (13) according to claim 1, wherein the electronic assembly (PE) comprises power electronics components.
16. The power transformer assembly (13) according to claim 1, wherein the heat dissipation means (P1, P2; P1, P2, P3) includes a third component (P3) positioned between the first component (P1) and the magnetic assembly (MA).
17. The power transformer assembly (13) according to claim 16, wherein the third component (P3) comprises a solid metal material.
18. The power transformer assembly (13) according to claim 16, wherein the third component (P3) comprises a porous metal material.
19. The power transformer assembly (13) according to claim 16, wherein the third component (P3) includes a metal layer.
20. The power transformer assembly (13) according to claim 16, wherein a sandwich configuration of three components (P1, P2, P3) consisting of the first component (P1), the second component (P2), and the third component (P3) is disposed 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).
21. The power transformer assembly (13) according to claim 1, wherein the duct (24) for the heat transfer fluid, defined by the material of the first component (P1), comprises a plurality of flow obstructions extending across the duct (24).
22. The power transformer assembly (13) according to claim 21, wherein at least a portion of the flow obstruction is integrally formed with the first component (P1).
23. The power transformer assembly (13) according to claim 21, wherein at least a portion of the flow obstruction is integrally formed with the second component (P2).
24. The power transformer assembly (13) according to claim 21, wherein at least a portion of the flow obstruction is integrally or monolithically formed with a third component (P3) disposed between the first component (P1) and the magnetic assembly (MA).
25. The power transformer assembly (13) according to claim 1, wherein the first component (P1) comprises functional parts (29, 30) integrally formed with the duct defining material of the first component (P1).
26. The power transformer assembly (13) according to claim 25, wherein the functional part includes 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.