Main coil assembly for grounding module GPM or vehicle module CPM in vehicle inductive charging systems

Abstract

The present invention relates to a main coil assembly for a grounding module (GPM) or a vehicle module (CPM) of a vehicle inductive charging system, the main coil assembly comprising a main coil (101), characterized in that the main coil (101) is designed to have at least one current conductor (102), the at least one current conductor (102) being arranged in a fluid-permeable volume between a first boundary surface (103) and a second boundary surface (104) of the main coil assembly so that fluid can flow around the current conductor (102), and the at least one current conductor (102) is guided / held in a predetermined coil shape and a predetermined coil position within the volume by individual, spaced-apart guiding and / or holding elements (105).

Description

[Technical Field]

[0001] The present invention relates to a main coil assembly for a grounding module GPM (GPM for "ground pad module") or a vehicle module CPM (CPM for "car pad module") of a vehicle inductive charging system, the main coil assembly consisting of at least one main coil. Typically, in an inductive charging system, energy is inductively transferred by the main coil of the grounding module GPM to the main coil of the vehicle module CPM located in the vehicle to charge an electrical storage device / battery and / or operate an electrical load. The grounding module GPM and the vehicle module CPM may also be configured for bidirectional energy transfer, from GPM to CPM and from CPM to GPM. [Background technology]

[0002] The GPM is typically mounted on the ground outside the vehicle, while the CPM is mounted on top of the vehicle, typically underneath. Electromagnetic coupling between the GPM's main coil and the CPM's main coil allows energy transfer from the GPM to the CPM, enabling charging of the vehicle's battery.

[0003] Both the GPM and CPM typically consist of their respective power electronics assembly and main coil assembly. To enable optimal electromagnetic coupling of the two main coils, the main coil of the GPM and the main coil of the CPM are optimally positioned relative to each other so that energy can be transferred inductively by the main coil of the ground module GPM to the main coil of the vehicle module CPM, or vice versa (bidirectionally). Summary of the Invention [Problem to be solved by the invention]

[0004] An object of the present invention is to provide a main coil assembly for a grounding module GPM or a vehicle module CPM of a vehicle inductive charging system, which assembly allows for a simple manufacturing process, reduced material usage, reliable product quality, and better cooling.

[0005] The invention arises from the features of the independent claims. Advantageous refinements and embodiments are the subject of the dependent claims. Other features, uses and advantages of the invention will become apparent from the following description and from consideration of exemplary embodiments of the invention depicted in the drawings. [Means for solving the problem]

[0006] This object is achieved by a main coil assembly for a grounding module GPM or a vehicle module CPM of a vehicle inductive charging system, the main coil assembly comprising a main coil, the main coil assembly being further characterized in that the main coil is designed to have at least one current conductor, the at least one current conductor being arranged in a volume allowing fluid to flow between a first boundary surface and a second boundary surface of the main coil assembly so that fluid can flow around the current conductor itself, and the at least one current conductor being guided / held in a predetermined coil shape and a predetermined coil position within the volume by individual and spaced apart guiding and / or holding elements.

[0007] The main coil is preferably designed as a flat coil. Advantageously, at least one current conductor of the flat coil is arranged in one plane. If the main coil has multiple current conductors, the multiple current conductors can advantageously be arranged in multiple planes aligned parallel to one another.

[0008] The first and second boundary surfaces are preferably aligned substantially parallel to each other. Advantageously, the first and / or second boundary surfaces are configured to be fluid-tight. When both boundary surfaces are designed to be fluid-tight, both the inflow and outflow of fluid occur laterally, for example, through a side surface perpendicular to the first and second boundary surfaces. Advantageously, the side surface is designed so that at least two areas of the side surface allow the inflow or outflow of fluid, while the remaining side area is fluid-tight. Advantageously, the fluid is ambient air.

[0009] Advantageously, a flow generator, e.g., a fan, propeller, etc., is present in the main coil assembly or an adjacent assembly to impart a flow velocity to the fluid as it enters or leaves the volume. Advantageously, the flow of the fluid within the volume is induced by targeted local flow influences. Such flow influences consist, for example, of targeted changes in local flow resistance within the flow-through volume, and / or targeted changes in local heat transfer between the fluid and the fluid flow interface, and / or targeted delay or excitation of local flow separation within the flow-through volume (i.e., targeted excitation of a transition from laminar to turbulent flow, for example).

[0010] Advantageously, flow-conducting elements (such as profiled elements) are arranged within the flow-through volume in order to have a specific influence on the local flow direction, bringing about a targeted change in the flow direction behind each element.

[0011] It is essential for improved cooling or dissipation of heat from the main coil assembly that the current conductors are arranged in the volume in such a way that fluid can flow around them. Advantageously, the fluid can flow completely around the surface of at least one current conductor of the main coil, i.e., up to the surface points of the current conductor that are covered by the guiding and / or retaining elements, as the case may be. Advantageously, the at least one current conductor is arranged in the volume in a substantially "free-floating" manner by the guiding and / or retaining elements.

[0012] In an advantageous embodiment, the at least one current conductor is arranged in contact with either the first or the second boundary surface, in which case the fluid advantageously flows around the surface of the at least one current conductor up to the contact surface of the current conductor on the respective boundary surface and, if applicable, up to the surface position of the current conductor that is covered by the guiding and / or retaining element.

[0013] The guiding and / or holding elements are individually arranged at a distance from one another and serve, on the one hand, to guide / hold at least one current conductor of the main coil into a predetermined coil shape and, on the other hand, to guide / hold at a predetermined coil or current conductor position within the volume.

[0014] Advantageously, the guide element and / or the holding element are at least partially designed as a spacer between and connecting the first and second boundary surfaces. Advantageously, the guide element and / or the holding element have a cylindrical shape. Advantageously, the guide element and / or the holding element are at least partially designed to locally fix the current conductor to the guide element and / or the holding element. For example, the guide element and / or the holding element each have a clip or other fixing mechanism for locally fixing the current conductor.

[0015] The guide and / or retaining elements are particularly advantageously designed to have a particular influence on the flow direction behind each guide and / or retaining element, so that the flow direction upstream of the guide and / or retaining element differs from the flow direction downstream behind the guide and / or retaining element. The influence of the flow within the volume is preferably performed in such a way that the fluid has the highest flow velocity, and thus the highest mass throughput, in the region of the volume where heat production by the main coil is highest during operation.

[0016] An advantageous further development is characterized in that at least one current conductor consists of at least one strand having a plurality of individual wires twisted together, each of the individual wires having an electrically non-conductive coating, and the strand having a plastic and / or silk sheath.

[0017] Advantageously, the current conductor consists of several twisted strands, the twisted strands having a plastic and / or silk sheath. Advantageously, the sheath is multi-layered, consisting of layers of different materials. The sheath advantageously consists of one or more of the following materials: ETFE: Ethylene-tetrafluoroethylene resin PTFE: Polytetrafluoroethylene plastic FEP: Ethylene propylene fluororesin. Polymer alloy: refers to a polymer alloy produced by mixing (blending) two or more types of polymers or copolymers. Polyamide: A linear polymer with regularly repeating amide bonds along the main chain. FR4: FR-4 or FR4 refers to a class of fire-resistant and flame-retardant composite materials made from epoxy resin and woven glass fiber.

[0018] The material of the current conductor forming the sheath of the strands is advantageously selected as follows: - Flammability is ensured in accordance with the UL94V-0 standard "Flammability Test for Plastic Materials for Appliance and Appliance Parts." This standard describes how to evaluate and classify the flammability of plastics. This standard has been incorporated with identical content into IEC / DIN EN 60695-11-10 and -20 and the Canadian CAN / CSA C 22.2 No. 017. The classification is based on the thickness of the test specimens at each stage of the horizontal burn test (HB), V-0, V-1, V-2, 5VA, and 5VB (vertical burn test). These classifications are as follows, in descending order of requirements: · HB: Slow burning of horizontally clamped specimens (self-extinguishing or thickness < 3 mm, speed < 75 mm / min (HB75), thickness 3...13 mm, speed < 40 mm / min (HB40)). V-2: The vertically clamped test piece will disappear within 30 seconds. Dripping of molten plastic is permitted. V-1: Same as V-2, but no burning dripping of molten plastic is permitted. Maximum afterflame of 60 seconds. V-0: Same as V-1, but flame goes out within 10 seconds. Maximum after-flame duration is 30 seconds. - the sheath of the current conductor held by the guide element and / or holding element is not subject to wear due to thermal expansion of the current conductor; -Sheath material resistance of at least 15 years; - Breakdown voltage of sheathed conductors is at least 3 kV; - The sheath is resistant to substances present in the road environment, in particular gasoline, diesel, synthetic oils, natural oils, salt water, cleaning fluids, brake fluids, etc.; - the water absorption rate into the sheath must be as low as possible and in no case the breakdown voltage must be less than 3 kV; -The sheathed conductor is thermally stable from -40°C to 100°C; - The minimum bending radius of the sheathed conductor is 70 mm; - the sheathed conductor is mechanically resistant to particles entrained in the fluid flow; -Sheathed conductors are UV resistant; -Sheathed conductors are resistant to ozone and other harmful gases present in the atmosphere near the ground.

[0019] Advantageously, the sheath of the current conductor has as high a thermal conductivity as possible.

[0020] A particularly preferred embodiment is characterized in that the current conductor comprises a plurality of twisted strands, each of which comprises a plurality of twisted individual wires, each of which has an electrically non-conductive coating, and the twisted strands have a first sheath made of a first polymer alloy and a second sheath made of a second polymer alloy applied thereon.

[0021] 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]

[0022] [Figure 1] 1 is a schematic diagram of a main coil assembly for a ground module GPM or a vehicle module CPM of a vehicle inductive charging system, the main coil assembly having a main coil 101 disposed on a first boundary surface 103 in a perspective view. [Figure 2] 1 is a schematic detailed perspective view of a main coil 101 disposed on a first boundary surface 103. FIG. [Figure 3] 1 is a schematic side view of a main coil 101 disposed between a first boundary surface 103 and a second boundary surface 104. FIG. DETAILED DESCRIPTION OF THE INVENTION

[0023] 1 shows a schematic diagram of a main coil assembly according to the invention for a grounding module GPM or a vehicle module CPM of a vehicle inductive charging system, the main coil assembly having a main coil 101 arranged on a first boundary surface 103. The main coil 101 is designed as a flat coil with a rounded rectangular spiral coil shape, with a current conductor 102. The current conductor 102 has electrical connections (circles) at both ends.

[0024] The current conductor 102 is disposed within a volume in which a fluid, in this case ambient air, can flow between a first boundary surface 103 and a second boundary surface 104 (not shown) of the main coil assembly so that the ambient air can flow around the current conductor 102.

[0025] Furthermore, the at least one current conductor 102 is guided and held in a predetermined coil shape and in a predetermined coil position within the volume by individual spaced apart guiding and / or holding elements 105 .

[0026] 2 is a schematic detail view showing in perspective view the main coil 101 arranged on the first boundary surface 103. The illustrated guiding and / or holding elements 105 have a cylindrical shape, and these cylindrical guiding and / or holding elements 105 guide and hold the current conductor 102 in a predetermined coil shape. The guiding and / or holding elements 105 may also be shown in the form of cable clips that hold the current conductor 102 in place. Finally, the guiding and / or holding elements 105* have a shape that, in addition to their function of guiding and holding the current conductor 102, is designed to intentionally influence the flow direction of the fluid, i.e., the flowing ambient air.

[0027] 3 is a schematic side view of a main coil 101 disposed between a first boundary surface 103 and a second boundary surface 104. In a volume between the first boundary surface 103 and the second boundary surface 104 through which outside air can flow, the current conductor 102 of the main coil 101 is disposed in contact with the first boundary surface.

[0028] 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 figures will enable those skilled in the art to practice the exemplary embodiments, and such persons may make various modifications in cognizance of the disclosed inventive concepts, e.g., 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, e.g., more extensive descriptions may be provided in the description. [Explanation of symbols]

[0029] 101: Main coil 102: Current conductor 103: First boundary surface 104: Second boundary surface 105: Guiding and / or holding elements

Claims

1. A main coil assembly for a ground module (GPM) or a vehicle module (CPM) of an inductive charging system for a vehicle, the main coil assembly comprising: a main coil (101); The main coil (101) is designed with at least one current conductor (102), the at least one current conductor (102) is disposed in a volume between a first boundary surface (103) and a second boundary surface (104) of the main coil assembly through which fluid can flow, such that fluid can flow around the current conductor (102); The at least one current conductor (102) is guided / retained in a predetermined coil shape and in a predetermined coil position within the volume by individual spaced apart guiding and / or retaining elements (105).

2. 2. The main coil assembly according to claim 1, characterized in that the guide and / or holding element (105) is at least partly designed as a spacer between the first boundary surface (103) and the second boundary surface (104) and connects them.

3. 3. A main coil assembly according to claim 1 or 2, characterized in that the guide and / or holding element (105) is designed as the guide element for guiding the fluid.

4. 3. A main coil assembly according to claim 1 or 2, characterized in that the guiding and / or holding elements (105) are at least partly designed for local fixing of the current conductor (102).

5. 2. The main coil assembly of claim 1, wherein the at least one current conductor (102) comprises at least one strand having a plurality of individual wires twisted together, each of the individual wires having an electrically non-conductive coating, and the strand having a sheath made of plastic and / or silk.

6. 6. The main coil assembly according to claim 5, wherein the current conductor (102) is made up of a plurality of twisted strands, and the twisted strands have a sheath made of the plastic and / or silk.

7. 7. The main coil assembly according to claim 5, wherein the sheath has a multi-layer structure made up of layers of different materials.

8. The sheath comprises: ETFE, PTFE, FEP, polymer alloy, polyamide, FR4, 8. The main coil assembly according to claim 5, wherein the main coil assembly is made of one or more of the following materials:

9. 2. The main coil assembly of claim 1, wherein the current conductor (102) is comprised of a plurality of strands twisted together, each of the strands having a plurality of the individual wires twisted together, each of the individual wires having an electrically non-conductive coating, and the twisted strands having a first sheath made of a first polymer alloy and a second sheath applied thereover made of a second polymer alloy.

10. 2. The main coil assembly of claim 1, wherein the fluid is ambient air.

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