Wireless charging module with cooling system
The wireless charging module addresses inefficient cooling by using separate cooling sections for electronic and magnetic subassemblies, optimizing coolant flow and structure for efficient heat dissipation, enhancing performance and reducing costs.
Patent Information
- Authority / Receiving Office
- JP · JP
- Patent Type
- Applications
- Current Assignee / Owner
- BRUSA ELEKTRONIK AG
- Filing Date
- 2024-07-01
- Publication Date
- 2026-07-03
AI Technical Summary
Existing cooling systems for wireless charging modules in electric vehicles are not well-suited to the unique heat-generating characteristics of electronic and magnetic subassemblies, are difficult to manufacture, and are expensive.
A wireless charging module with a cooling system featuring separate cooling sections for the electronic and magnetic subassemblies, optimized for different heat dissipation needs, utilizing a coolant flow structure with varying channel shapes and wall structures to distribute coolant effectively.
The cooling system efficiently dissipates heat from both subassemblies, optimizing coolant flow to maximize heat dissipation, thereby improving the module's performance and reducing manufacturing complexity and costs.
Smart Images
Figure 2026521994000001_ABST
Abstract
Description
Technical Field
[0001] The present invention relates to a wireless charging module for charging a battery or supplying power to an electrical load of a vehicle.
Background Art
[0002] The battery of an electric vehicle can be charged with alternating current (AC) or direct current (DC). A typical AC charging device can provide a charging power of up to 22 kW. The AC charging system can be subdivided into a cable-connected charging system and a cableless charging system, and the cableless charging system is mainly designed as an inductive charging system (ICS). Generally, a cable-connected AC charging device is incorporated into an electric vehicle and is also called an in-vehicle charging device. Generally, the ICS often consists of two separate modules, often called a ground pad module (GPM) and a car pad module (CPM). The GPM is installed outside the electric vehicle, while the CPM is installed inside the electric vehicle, generally under the vehicle. The electromagnetic interaction between the GPM and the CPM enables energy transmission from the GPM to the CPM and vice versa, and then the CPM is used to charge the battery of the electric vehicle. The cableless charging system is generally more comfortable for the user because it generally does not require manual intervention to start the battery charging procedure, except for placing the vehicle on the GPM.
Summary of the Invention
[0003] The wireless charging module according to the present invention can be used particularly for charging a high-voltage battery or supplying power to an electrical load of a vehicle. In this case, it can be called a car pad module (CPM). This can receive an oscillating magnetic field from an external emitter, which can be called a ground pad module (GPM). The CPM converts the oscillating electromagnetic field, mainly the magnetic field, into an alternating current, and the alternating current is converted (typically rectified), thereby resulting in a charging current (typically direct current) used for charging the battery or supplying power to the electrical load.
[0004] A wireless charging module can also be called a power converter. It helps convert the electromagnetic energy of an oscillating electromagnetic field into electric power, or electric power that can be used to charge a power storage device or to power an electrical load.
[0005] Regarding cooling, it is important to understand that a CPM can include two heat-generating regions: an electronic subassembly (power electronics) that generates a lot of heat but is concentrated in a specific location within the device and has relatively high-density heat-generating elements, and a magnetic subassembly (coils and ferrite) that generates less heat but is spatially dispersed to a relatively high degree and therefore has low-density heat-generating elements.
[0006] Existing cooling systems for CPMs are not well-suited to these conditions, are relatively difficult to manufacture, and therefore expensive.
[0007] Therefore, the object of the present invention is to create the type of wireless charging module described earlier that overcomes the aforementioned drawbacks.
[0008] This objective is achieved by a wireless charging module having the features of patent claim 1.
[0009] A wireless charging module is useful for charging the battery and / or supplying power to the vehicle's electrical load. Additionally or alternatively, it can be applied to transmit electrical energy from the vehicle. It includes the following: • A first, in particular, magnetic subassembly for receiving an oscillating electromagnetic field and converting it to an alternating current, • A second, particularly an electronic subassembly, for receiving alternating current and converting it to current for charging a battery or supplying power to an electrical load. A cooling system for dissipating heat generated by two subassemblies during operation by the flow of coolant between a first coolant connection and a second coolant connection of the cooling system.
[0010] The cooling system comprises a cooling channel structure having at least one coolant channel and at least two cooling sections. • At least one first cooling section positioned to dissipate heat from the magnetic subassembly, • At least one second cooling section positioned to dissipate heat from at least the electronic subassembly.
[0011] Here, the two cooling sections have different shapes so that the second cooling section dissipates more heat flow than the first cooling section.
[0012] Therefore, the first cooling section helps to dissipate the heat generated by the magnetic subassembly during its operation, and the second cooling section helps to dissipate the heat generated by the second electronic subassembly during its operation. Since the two cooling sections are designed to dissipate different heat flows, and therefore different amounts of heat per unit time, the cooling operation can be optimized according to the different large amounts of heat generated from the two subassemblies. This means that the flow of coolant through the cooling channel structure is distributed to the two cooling sections so that at least nearly the maximum heat flow can be dissipated from the two subassemblies.
[0013] The fact that the cooling system includes a flow of coolant between a first coolant connection and a second coolant connection means that cooling is performed by a single flow of coolant, and this flow of coolant can be divided into different sections running in parallel and / or sequentially directed through cooling sections having different characteristics.
[0014] In the embodiment, the cooling channel structure is positioned between at least one first portion and a second portion, and one or more channels of the cooling channel structure are formed by recesses in the first portion and / or the second portion. In particular, the first portion and / or the second portion are plate-like or broadly extending.
[0015] Therefore, the first and second parts are applied to each other to form a semishell that forms a cooling channel structure having one or more coolant channels.
[0016] In the embodiment, the first and second cooling sections are arranged in coolant channels that extend parallel to each other in at least some regions.
[0017] In this embodiment, the first and second cooling sections are positioned along the same coolant channel, and the positions are continuous in the flow direction.
[0018] Therefore, two or more cooling sections can exist. If there is only one coolant channel, the cooling sections are positioned along this channel. If there are two or more coolant channels, the cooling sections can be positioned along different coolant channels.
[0019] In this embodiment, the first and second cooling sections have different wall structures. In particular, they are as follows: On the one hand, the first cooling section in particular has smooth walls, while on the other hand, the second cooling section in particular has structured walls, or On the one hand, the first cooling section in particular has a structured wall, while on the other hand, the second cooling section in particular has a smooth wall, or On the one hand, the first cooling section in particular is equipped with a structured wall, while on the other hand, the second cooling section in particular is equipped with a different structured wall.
[0020] The wall can be structured to be different depending on the density of obstacles or vortical structures of the same shape. In an embodiment, regions with different heat dissipation requirements exist along the coolant channel, and thus the assigned cooling sections have vortical structures that are equally shaped but have different densities.
[0021] In an embodiment, the cooling channel structure comprises at least two coolant channels that extend parallel to each other and are designed to guide different distributions of the coolant flow. In particular, the coolant flow through the first cooling section is less than half or one-third or one-fourth or one-fifth of the coolant flow through the second cooling section.
[0022] Thereby, the coolant flow can be split between the two cooling sections according to the amount of heat to be dissipated. This can be achieved, for example, by two coolant channels and / or the shape of the branching region having different flow cross-sectional areas and / or flow resistances, where in the branching region, the coolant flow actually led from the first coolant connection or the second coolant connection to the two parallel coolant channels is split into the coolant channels.
[0023] The ratio of the coolant flow during the operation of the charging module should be understood with respect to the nominal value of the complete coolant flow corresponding to the nominal operating power of the charging module.
[0024] In an embodiment, at least one of the cooling sections comprises a structure on at least one channel wall for swirling the coolant flow. In particular, the structure is integrally formed on the channel wall as a single body.
[0025] In an embodiment, the structure within the region of at least one cooling section protrudes into the coolant channel and forms an obstacle that reduces the flow cross-sectional area of the coolant channel compared to the adjacent section.
[0026] In an embodiment, the structure divides the coolant channel into two or more of the following partial channels having a parallel flow. · In particular, a partial channel whose shape is different from a path having a straight line or a constant curvature, · In particular, a partial channel having a wavy, zigzag or serpentine path.
[0027] In an embodiment, at least one of the first part and the second part forms a support structure for supporting at least one of the magnetic subassembly and the electronic subassembly.
[0028] In an embodiment, it is at least one of the following states. · The magnetic subassembly is assembled on the first part or the second part adjacent to the first cooling section and optionally also adjacent to the second cooling section. · The electronic subassembly is assembled on the first part or the second part adjacent to the second cooling section.
[0029] Further preferred embodiments can be derived from the dependent claims.
[0030] The subject matter of the present invention will be described in more detail through examples of preferred embodiments represented in the accompanying drawings. In each case, the following is schematically shown.
Brief Description of the Drawings
[0031] [Figure 1] A garage having a vehicle on a cableless charging station. [Figure 2] A cableless charging station and a cableless charging device. [Figure 3] A cableless charging device. [Figure 4] A cross-sectional view of a cableless charging device. [Figure 5] The shape of the cooling channel structure in the cooling system. [Figure 6] A cableless charging device that is partially uncovered. [Figure 7] One shape of the structured wall structure. [Figure 8] Different shapes of structural wall structures. [Modes for carrying out the invention]
[0032] The reference numbers used in the drawings and their meanings are listed in the reference number list. Generally, identical or functionally equivalent parts in a drawing are assigned the same reference number.
[0033] The plan view in Figure 1 shows a garage 1 in which vehicle 2 is parked, with a cableless charging station 3 located outside the vehicle 2 and equipped with an emitter for transmitting vibrational magnetic fields, above it. The charging station 3 is visible because vehicle 2 is represented transparently. Such a charging solution is very convenient, and the driver is freed from connecting and disconnecting charging cables.
[0034] Figure 2 is an enlarged view of Figure 1, showing a cableless charging station 3 and a cableless charging device 4 "floating" above the charging station 3 for charging the vehicle's high-voltage battery 5. The aforementioned charging device 4 is installed on the vehicle, which means that the rest of the vehicle is not visible in this figure.
[0035] Figure 3 shows a perspective view of the charging device 4.
[0036] Figure 4 shows a schematic cross-sectional view of a cableless charging device 4, which may also be called a wireless charging module. The first part 41 and the second part 42 form a support structure for components to be further described. The first part 41 and / or the second part 42 may each consist of several separate parts. Furthermore, a housing, which is not shown, may also exist. The electronic subassembly 7 is located on the first part 41. This results in a relatively large amount of waste heat in a relatively small space. The magnetic subassembly 6 is located on or within the second part 42. This comprises coil leads 62 and ferrite elements 61. These result in a relatively small amount of waste heat that is distributed over a larger space.
[0037] The coolant channel 90 of the cooling channel structure 9 is formed between a first portion 41 and a second portion 42 by recesses in one or both of these portions. The coolant channel 90 can be sealed by a sealing element 49. The coolant channel 90 comprises a first cooling section 91 that primarily cools a portion of the magnetic subassembly 6, and a second cooling section 92 that cools the electronic subassembly 7 and, in this embodiment, also cools a portion of the magnetic subassembly 6. Thus, the second cooling section 92 is designed to dissipate a larger amount of heat per unit time than the first cooling section 91.
[0038] Various methods are possible to achieve these different heat dissipations using a common coolant source. These can be achieved individually or in combination. • Coolant channels 90 can exist that extend parallel to each other and carry coolant flows of different sizes. To realize these different coolant flows, the coolant channels 90 can have different fluid resistances, in particular, different cross-sections. Furthermore, branches can be formed into the coolant channels so that a desired division of the coolant flow 80 is realized. • Cooling sections with different heat transfer characteristics to the channel wall may exist. Such different cooling sections can be arranged in series within the same coolant channel 90. They can also be arranged in parallel within the coolant channel 90.
[0039] The cooling channel structure 9, together with the first coolant connection portion 81 and the second coolant connection portion 82, forms the cooling system 8 of the cableless charging device 4.
[0040] Figure 5 shows the shape of the cooling channel structure 9 within the cooling system 8. Here, only the shape of the cavity of the cooling system 8 is represented in wireframe form, omitting the shapes of the surrounding elements. The cooling channel structure 9 in Figure 5 comprises two parallel coolant channels, the first of which forms the first cooling section 91, and the second channel forms the second cooling section 92. The first cooling section 91 has a smaller cross-section and a smaller first coolant flow 80a than the second cooling section 92, which has a larger second coolant flow 80b. This cooling channel structure 9 and the surrounding elements may have cross-sections as shown in Figure 4 (structured wall structures are not shown in Figure 5).
[0041] In this embodiment, the fluid resistance and / or branching of the parallel coolant channels 90 are designed such that the division of the coolant flow 80 into the two coolant channels 90 is the same regardless of the flow direction.
[0042] The design of the shape at the branch between the first cooling section 91 and the second cooling section 92 allows for control over the distribution of the coolant flow 80 to both. The channel has a smooth wall structure 43, meaning the channel walls are inherently smooth and do not create vortices in the coolant flow 80.
[0043] Figure 6 shows a partially uncovered cableless charger 4, with the second part 42 as well as the magnetic subassembly 6 and sealing element 49 removed. A complete cableless charger 4 can have a cross-section like that shown in Figure 4. In the coolant channel, the first cooling section 91 and the second cooling section 92 are arranged in succession and sequentially receive through flow by the same coolant flow 80. As already mentioned, waste heat from the electronic subassembly 7 is dissipated in the second cooling section 92. For this purpose, there is a vortex structure, in this case a cylindrical projection on the channel wall formed by the first part 41. To accommodate the different amounts of waste heat in the electronic subassembly 7, the first region 45a has a higher density of vortex structures than the second region 45b.
[0044] Figures 7 and 8 show various shapes of the structured wall structure 44. The structured wall structure 44 includes an obstacle or vortex structure 45 that creates vortices in the coolant flow 80, thereby improving heat transfer to the channel wall and the vortex structure 45 itself. The vortex structure 45 can be molded on the channel wall and therefore designed integrally with the channel wall to improve heat transfer to the channel wall. Alternatively, they can be bonded to the channel wall by material fit coupling.
[0045] In Figure 7, the vortex structure 45 is a projection that protrudes into the coolant flow 80. The projection may be cylindrical, particularly cylindrical in shape. The cooling section can be adapted to the amount of heat to be dissipated by the density of projections of equal shape, i.e., the number of projections per unit surface area of the channel wall.
[0046] In Figure 8, the vortex structure 45 forms parallel partial channels 93 having wavy or zigzag paths. [Explanation of Symbols]
[0047] 1...Garage, 2...Vehicle, 3...Charging station, 4...Cableless charging device, 41...First part, 42...Second part, 43...Smooth wall structure, 44...Structured wall structure, 45...Vortex structure, 49...Sealing element, 5...Battery, 6...Magnetic subassembly, 61...Ferrite element, 62...Coil lead, 7...Electronic assembly, 8...Cooling system 80...Coolant flow, 81...First coolant connection, 82...Second coolant connection, 9...Cooling channel structure, 90...Coolant channel, 91...First cooling section, 92...Second cooling section, 93...Partial channel.
Claims
1. A wireless charging module for charging a battery (5) of a vehicle (2), and / or supplying power to an electrical load of the vehicle (2), and / or delivering energy from the battery (5) of the vehicle (2), and / or delivering energy to an energy source of the vehicle (2), A first, in particular, magnetic subassembly (6) for receiving an oscillating electromagnetic field and converting it to an alternating current, A second, in particular, electronic subassembly (7) for receiving the alternating current and converting it into a current for charging the battery (5) or supplying power to the electrical load, The cooling system (8) is configured to dissipate the heat generated by the two subassemblies (6, 7) during their operation by the flow of coolant (80) between the first coolant connection (81) and the second coolant connection (82) of the cooling system (8), The cooling system (8) comprises a cooling channel structure (9) having at least one coolant channel (90) and at least two cooling sections (91, 92), and the two cooling sections (91, 92) At least one first cooling section (91) is provided to dissipate heat from the magnetic subassembly (6), The system includes at least one second cooling section (92) arranged to dissipate heat from at least the electronic subassembly (7), A wireless charging module in which the two cooling sections (91, 92) have different shapes so that the second cooling section (92) releases a larger heat flow than the first cooling section (91).
2. The cooling channel structure (9) is positioned between at least one first portion (41) and a second portion (42), and one or more channels (90) of the cooling channel structure (9) are formed by recesses in the first portion (41) and / or the second portion (42). In particular, the wireless charging module (4) according to claim 1, wherein the first portion (41) and / or the second portion (42) are plate-shaped or extend over a wide area.
3. The wireless charging module (4) according to claim 1 or 2, wherein the first and second cooling sections (91, 92) are arranged in a plurality of cooling channel (90) that extend parallel to each other in at least some areas.
4. The wireless charging module (4) according to any one of claims 1 to 3, wherein the first and second cooling sections (91, 92) are arranged at multiple positions along the same coolant channel (90), and the multiple positions are continuous in the flow direction.
5. The first and second cooling sections (91, 92) have different wall structures, especially On the one hand, the first cooling section (91) is provided with a smooth wall (43), and on the other hand, the second cooling section (92) is provided with a structured wall (44), or On the one hand, the first cooling section (91) is provided with a structured wall (44), and on the other hand, the second cooling section (92) is provided with a smooth wall (43), or On the one hand, the first cooling section (91) is provided with a structured wall (44), and on the other hand, the second cooling section (92) is provided with a different structured wall (44), according to any one of claims 1 to 4.
6. The cooling channel structure (9) comprises at least two coolant channels (90) extending parallel to each other, which are designed to guide different distributions of the coolant flow (80). In particular, the wireless charging module (4) according to any one of claims 1 to 5, wherein the flow of coolant (80a) through the first cooling section (91) is less than half, one-third, one-quarter, or one-fifth of the flow of coolant (80b) through the second cooling section (92).
7. At least one of the cooling sections (91, 92) is provided with a structure (45) on at least one channel wall for vortexing the flow of the coolant, In particular, the wireless charging module (4) according to any one of claims 1 to 6, wherein the structure is integrally formed on the channel wall as a single component.
8. The wireless charging module (4) according to claim 7, wherein the structure within the region of at least one cooling section (91, 92) protrudes into the coolant channel (90) and forms a plurality of obstacles that reduce the flow cross-sectional area of the coolant channel (90) compared to adjacent sections.
9. The above structure divides the coolant channel (90) into two or more partial channels (93) having parallel flow, In particular, a partial channel (93) whose shape is different from a straight line or a path having a constant curvature, In particular, it is divided into partial channels (93) having wavy, zigzag, or meandering paths. The wireless charging module (4) according to claim 7 or 8.
10. A wireless charging module (4) according to any one of claims 1 to 9, dependent on claim 2, wherein at least one of the first portion (41) and the second portion (42) forms a support structure for supporting at least one of the magnetic subassembly (6) and the electronic subassembly (7).
11. The magnetic subassembly (6) is assembled on the first portion (41) or the second portion (42), adjacent to the first cooling section (91) and optionally adjacent to the second cooling section (92). The electronic subassembly (7) is assembled on the first portion (41) or the second portion (42) adjacent to the second cooling section (92). A wireless charging module (4) according to any one of claims 1 to 10, which is in at least one of the above states.