Vehicle module CPM for inductive charging systems for vehicles

Abstract

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

Description

[Technical Field]

[0001] The present invention relates to a vehicle module CPM of an inductive charging system for a vehicle. Furthermore, the present invention relates to an inductive charging system for a vehicle for charging an electric storage device of the vehicle, comprising at least one ground module GPM and a vehicle module CPM of the same type. Furthermore, the present invention relates to a vehicle equipped with such a vehicle module CPM. [Background technology]

[0002] As is well known, an inductive charging system for a vehicle typically comprises a grounding module (ground pad module; GPM) that is fixed to the ground and connected to a power grid, and a vehicle module (car pad module; CPM) that is typically located underneath the vehicle. Typically, in such an inductive charging system, energy is inductively transferred by a main coil of the grounding module GPM to a main coil of a vehicle module CPM located on the vehicle to charge an electrical storage device / battery and / or supply an electrical load. The grounding module GPM and the vehicle module CPM may also be configured for bidirectional energy transfer, from the GPM to the CPM and from the CPM to the GPM.

[0003] Both GPMs and CPMs typically include a main coil assembly with an electronic assembly and a main coil. The main coil of the GPM and the main coil of the CPM must be optimally positioned relative to each other to allow optimal electromagnetic coupling of the two main coils for energy transfer.

[0004] During operation, i.e., during energy transfer from main coil to main coil, GPMs and CPMs generate heat in essentially two areas: (a) each electronic assembly generates a lot of heat that is relatively concentrated in specific locations with high local heat density, and (b) each main coil assembly (main coil and ferrite) generates a small amount of heat that is relatively well distributed relative to the electronic assembly. The electronic assembly typically consists of power electronics. Summary of the Invention [Problem to be solved by the invention]

[0005] SUMMARY OF THE INVENTION It is an object of the present invention to provide a vehicle module CPM with improved cooling at low cost.

[0006] The invention arises from the features of the independent claims. Advantageous refinements and embodiments are the subject of the dependent claims. Other features, possible applications and advantages of the invention will become apparent from the following description and from a consideration of exemplary embodiments of the invention depicted in the drawings. [Means for solving the problem]

[0007] A first aspect of the present invention relates to a vehicle module (CPM) of an inductive charging system for a vehicle, comprising: a main coil assembly for converting a received electromagnetic field into an alternating current; an electronic assembly for converting the alternating current into a direct current; and heat dissipation means having an outer surface made of an electrically non-conductive plastic material, the outer surface being in thermal contact with the main coil assembly and / or the electronic assembly, the outer surface dissipating heat generated by the main coil assembly and / or the electronic assembly to the environment during power conversion operation, the outer surface being formed by a plurality of structural elements individually arranged on a smooth, unstructured reference surface of the outer surface, each structural element being raised above the reference surface. The separated structural elements provide an enlarged surface, resulting in improved heat transfer to the environment, in particular the surrounding air.

[0008] The structural elements are preferably arranged either exclusively evenly, exclusively unevenly or randomly on at least a part of the reference plane. The reference plane can in particular be a virtual reference plane assigned to the outer surface, from which all the structural elements extend in a raised form.

[0009] Advantageously, the vehicle module CPM has a housing with an outer housing surface, and the structured outer surface is present in the region of the outer housing surface that forms the lower surface of the vehicle when the vehicle module CPM is attached to the vehicle. The heat generated during power conversion in the CPM is dissipated to the ambient air via this outer housing surface located on the lower surface of the vehicle. The structural elements are preferably designed such that they remain largely undamaged in the event of an external mechanical impact on the outer housing surface, for example due to a stone impact or due to the vehicle coming to rest on the outer housing surface.

[0010] Advantageously, the structural elements are arranged directly adjacent to each other as a defect-free array or spaced apart from each other as a defect-free array on the reference plane, preferably arranged in rows and columns.

[0011] Advantageously, all the structural elements have the same three-dimensional shape. In an alternative embodiment, at least some of the structural elements are designed to be different with respect to their three-dimensional shape.

[0012] Particularly preferably, the reference surface extending from each structural element outer surface and the reference surface of the structural elements includes an inclination angle (NW) in the range of 0° < NW < 90° or 30° < NW < 60°, particularly an inclination angle NW = 45°. Even more preferably, the immediately adjacent inclined structural element outer surfaces of different structural elements enclose an angle (WE) in the range of 90° ≤ WE < 180° or 90° < WE < 150° or 90° < WE < 120°, or the angle WE is particularly equal to 90°. This ensures that the heat radiation emitted from the structural element outer surface is essentially radiated to the environment and does not heat the adjacent structural element outer surfaces.

[0013] Particularly advantageously, at least one, some or all of the structural elements are designed as pyramidal or conical or hipped roof elements, with their respective bases (of the pyramids, cones or hipped roof elements) lying on a reference plane. The tips of the respective pyramids or cones can be rounded.

[0014] In another advantageous embodiment, at least one, some or all of the structural elements are designed as truncated pyramids or as truncated cones or mansard flat roofs, with the respective base surfaces (of the truncated pyramids or truncated cones or mansard flat roofs) being located on a reference plane.

[0015] The pyramid or truncated pyramid may advantageously have a triangular, quadrangular, hexagonal or octagonal base.

[0016] An advantageous further development of the vehicle module CPM is characterized in that the outer surface is mainly or exclusively made up of structural elements designed in a pyramidal, conical or hipped roof style, which provides "soft" impact protection in the event of external mechanical impacts on the outer surface of the housing, albeit with reduced wear resistance.

[0017] An advantageous further development of the CPM vehicle module is characterized in that the outer surface is mainly or exclusively made up of structural elements designed in the shape of a truncated pyramid, truncated cone, or mansard roof. In the event of an external mechanical impact on the outer surface of the housing, a "hard" impact protection with relatively high wear resistance is formed.

[0018] An advantageous further development of the CPM vehicle module is characterized in that the outer surface in one area alternates between structural elements designed as pyramidal, conical or hipped roofs and structural elements designed as truncated pyramidal, conical or flat mansard roofs. This provides "medium" impact protection with medium abrasion resistance in the event of mechanical impacts on the outer surface of the housing.

[0019] Advantageously, the outer surface of the heat dissipation means consists of an electrically non-conductive material. Advantageously, the outer surface of the heat dissipation means is manufactured by molding, casting or injecting material into a mould. Advantageously, the outer surface of the heat dissipation means is manufactured by sintering a sinterable material in a mould. Advantageously, the outer surface of the heat dissipation means is manufactured by cross-linking a cross-linkable material in a mould. Advantageously, the outer surface of the heat dissipation means is manufactured additively in a layer-by-layer application process. Advantageously, the outer surface of the heat dissipation means consists of a polymer material. Advantageously, the outer surface of the heat dissipation means consists of a ceramic material. Advantageously, the outer surface of the heat dissipation means consists of a composite material. Advantageously, the outer surface of the heat dissipation means consists of a fibre-reinforced polymer matrix, the fibres consisting of an electrically non-conductive material. Advantageously, the outer surface of the heat dissipation means consists of a polymer matrix having particles dispersed therein, the fibres consisting of an electrically non-conductive material. Advantageously, the electrically non-conductive material is selected from at least one of boron nitride, silicon carbide.

[0020] A second aspect of the invention relates to an inductive charging system for a vehicle for charging an energy storage device of the vehicle, comprising at least one ground module GPM and one vehicle module CPM, wherein energy is transferred at least between the ground module GPM and the vehicle module CPM, and the vehicle module CPM is designed as described above.

[0021] A third aspect of the invention relates to a vehicle equipped with a vehicle module CPM as described above.

[0022] Further advantages, features and details will become apparent from the following description, in which identical, similar and / or functionally identical parts are designated with the same reference numerals. [Brief explanation of the drawings]

[0023] [Figure 1] 2 is a diagram showing a schematic view of a part of the outer surface of the heat dissipation means of the vehicle module CPM according to the present invention; FIG. [Figure 2]1 is a schematic view of a vehicle module CPM with a housing that is also part of a heat dissipation means, with a structured housing outer surface according to the invention; [Figure 3] 1 is a schematic diagram showing the internal structure of a vehicle module CPM with a main coil assembly 105 and an electronic assembly 106. FIG. DETAILED DESCRIPTION OF THE INVENTION

[0024] 1 shows a schematic view of a portion of the outer surface of the heat dissipation means of the vehicle module CPM according to the present invention. The outer surface and structural elements 103 are made of an electrically non-conductive plastic material, which is advantageously a good thermal conductor. This plastic material is in thermally conductive contact with the main coil assembly and / or electronic assembly, and the outer surface 101 dissipates heat generated during the power conversion operation of the main coil assembly 105 and electronic assembly 106 into the ambient air.

[0025] On a flat reference surface 101 (here spanned by the two vectors shown), a plurality of individually arranged structural elements 103, each raised above the reference surface 102, are arranged in the form of adjacent pyramids with a rectangular base area.

[0026] The reference plane 102 and each structural element outer surface 104 of the structural elements 103 extending from the reference plane 102 here enclose an inclination angle (NW) of about 45°. Thus, the inclined structural element outer surfaces 104 of different structural elements 103 arranged directly adjacent (opposite each other) are inclined relative to each other at an angle (WE) of about 90°. Thermal radiation emitted from the structural element outer surfaces 104 does not substantially heat the outer surface 101.

[0027] Figure 2 shows a schematic perspective view of a vehicle module CPM with a CPM housing. When installed in a vehicle, the structured surface of the CPM housing shown in Figure 2 is positioned facing downwards on the vehicle floor. The structured outer surface 101 of the CPM housing is also part of the heat dissipation means. The structured outer surface 101 of the housing has a plurality of pyramidal structural elements 103, which are arranged in a matrix in rows and columns directly adjacent to each other.

[0028] 3 is a schematic diagram showing the internal structure of a vehicle module CPM comprising a main coil assembly 105 and an electronic assembly 106. The main coil assembly comprises in particular a main coil, in this case designed as a flat coil.

[0029] While the present invention has been further illustrated and described in detail by preferred exemplary embodiments, the present invention is not limited to the disclosed examples, and those skilled in the art may derive other modifications therefrom without departing from the scope of the present invention. Thus, it is apparent that various possible modifications exist. It is also apparent that the illustrated embodiments are merely exemplary in nature and should not be construed in any way as limiting the scope, applicability, or configuration of the present invention. Rather, the foregoing description and drawings will enable one skilled in the art to practice the exemplary embodiments, and such a person, knowing the disclosed inventive concepts, may make various modifications, such as making more extensive statements in the description, with respect to the function or arrangement of individual elements recited in the exemplary embodiments, without departing from the scope defined by the claims and their legal equivalents. [Explanation of symbols]

[0030] 101: outer surface of heat dissipation means 102: Reference plane 103: Structural elements 104: Structural element outer surface 105: Main coil assembly 106: Electronic Assembly

Claims

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

2. 2. Vehicle module CPM according to claim 1, wherein said structural elements (103) are arranged exclusively in a uniform or non-uniform distribution on at least a portion of said reference surface (102).

3. 3. The vehicle module CPM of claim 1 or 2, wherein the vehicle module CPM has a housing having a housing outer surface, and the structured outer surface (101) is present in an area of ​​the housing outer surface that forms a vehicle underside when the vehicle module CPM is installed in a vehicle.

4. 3. A vehicle module CPM according to claim 1 or 2, wherein said structural elements (103) are respectively arranged directly adjacent to one another in a defect-free array on said reference surface (102).

5. 3. Vehicle module CPM according to claim 1 or 2, wherein the structural elements (103) are arranged at a distance from one another in a defect-free array on the reference surface (102).

6. 3. Vehicle module CPM according to claim 1 or 2, wherein said structural elements (103) are arranged in rows and columns on said reference surface (102).

7. 3. The vehicle module CPM of claim 1, wherein each structural element outer surface (104) of the structural element (103) extending from the reference surface (102) and the reference surface (102) encompasses a tilt angle (NW) in the range of 0°<NW<90° or 30°<NW<60°, or the tilt angle (NW) is 45°.

8. 3. A vehicle module CPM according to claim 1 or 2, wherein the inclined structural element outer surfaces (104) of different structural elements (103) arranged directly adjacent to each other respectively enclose an angle (WE) in the range 90°≦WE<180° or 90°<WE<150° or 90°<WE<120°, or the angle (WE) is in particular equal to 90°.

9. 3. The vehicle module CPM according to claim 1 or 2, wherein at least one, some or all of the structural elements (103) are designed as a pyramid or as a cone or a hipped roof, respectively, and the base of the pyramid or the cone or the hipped roof, respectively, is arranged on the reference plane (102).

10. 3. Vehicle module CPM according to claim 1 or 2, wherein at least one, some or all of the structural elements (103) are designed as a truncated pyramid or as a truncated cone or a mansard flat roof, respectively, and the bottom surface of the truncated pyramid or the truncated cone or the mansard flat roof, respectively, is arranged on the reference surface (102).

11. 1. An inductive charging system for a vehicle for charging an electrical storage device of the vehicle, comprising at least one ground module GPM and one vehicle module CPM, wherein energy is transferred between the ground module GPM and the vehicle module CPM, the vehicle module CPM being designed according to claim 1 or 2.

12. A vehicle equipped with a vehicle module CPM according to any one of claims 1 to 10.

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