Manufacturing method of coil module and coil assembly

Abstract

The coil module (M) has a polygonal basic shape with 4 to 12 corners (p1 to p8) and is composed of a carrier (2) made of a magnetic material. A coil (3) is placed on the carrier (2). The polygonal basic shape has rotational symmetry with an angle of 360°·2 divided by the number of corners (p1 to p8). To manufacture the coil assembly (1), multiple coil modules (M) can be connected to each other. This allows for the simple and flexible manufacture of efficient coil assemblies (1) for wireless electromagnetic energy transmission.

Description

Technical Field

[0001] The content of German Patent Application DE 10 2020 201 753.0 is incorporated herein by reference.

[0002] The present invention relates to a coil module for manufacturing a coil assembly and a coil assembly having at least two such coil modules. Furthermore, the present invention relates to a method for manufacturing a coil assembly.

Background Art

[0003] Devices for wirelessly and electromagnetically transmitting energy are known from Patent Document 1. This device is useful, for example, for charging an electric vehicle. This device is composed of a stationary base charging system and a vehicle charging system arranged on the electric vehicle. The base charging system is composed of, for example, two coils arranged side by side on a ferrite plate and connected to each other.

[0004] A wireless charging device is known from Patent Document 2. This charging device is composed of a magnetic core and a coil arranged thereon. The magnetic core is composed of bars arranged in a triangular or star shape.

Prior Art Documents

Patent Documents

[0005]

Patent Document 1

Patent Document 2

Summary of the Invention

Problems to be Solved by the Invention

[0006] An object of the present invention is to provide a coil module capable of simply and flexibly manufacturing an efficient coil assembly for wireless electromagnetic energy transmission.

Means for Solving the Problem

[0007] This object is achieved by a coil module having the features described in claim 1. Due to the polygonal basic shape of the carrier, the coil module according to the invention enables the coil assemblies of a plurality of coil modules to be manufactured in a simple and flexible manner. Due to the polygonal basic shape, the carriers of the coil modules can be arranged adjacent to each other and / or fixed to each other in a simple and flexible manner. Preferably, 6 ≤ N ≤ 10, in particular N = 8, applies. Geometrically speaking, the carrier must in principle have a polygonal basic shape. However, the carrier may have rounded corners (radius R) and / or edges, for example for manufacturing reasons, and may deviate slightly from the polygonal shape. Since it is rotationally symmetric, the coil modules can be arranged adjacent to each other in a simple and flexible manner for manufacturing the coil assembly.

[0008] The coil is arranged on the carrier to generate an electromagnetic field. Preferably, the coil module is composed of exactly one coil. The coil is preferably arranged within the polygonal basic shape. In other words, the windings of the coil do not extend laterally beyond the carrier. For manufacturing the coil assembly, the coils of the coil modules can be simply and flexibly connected in series and / or in parallel. Therefore, the electrical characteristics of the coil assembly can be simply and flexibly adapted in a desired manner. By the carrier being composed of a magnetic material, the electromagnetic field can be induced and / or shielded in a simple and flexible manner. Preferably, the magnetic material is a ferrite material. In particular, the ferrite material consists of manganese and zinc. Preferably, the carrier is formed of a magnetic material.

[0009] The coil module according to the invention enables a coil assembly having a substantially random shape to be manufactured in a simple manner. Due to the shape and / or interconnection of the coil modules, each coil assembly can be flexibly adapted to the desired application, so that high efficiency can be achieved in wireless electromagnetic energy transmission.

[0010] The coil module according to claim 2 ensures easy and flexible manufacturing of an efficient coil assembly. Preferably, the number N is selected from the set of numbers 4, 6, 8, 10, and 12. Preferably, the basic shape is an octagon, i.e., an octagon with N = 8.

[0011] The coil module according to claim 3 ensures easy and flexible manufacturing of an efficient coil assembly. Preferably, the basic shape is regular. A regular basic shape means that the polygon is equilateral and equiangular. Preferably, the basic shape is a square, a regular hexagon, a regular octagon, a regular decagon, or a regular dodecagon.

[0012] The coil module according to claim 4 ensures easy and flexible manufacturing of an efficient coil assembly. The carrier preferably has a planar shape. The carrier consists of an upper surface, a lower surface, and a side surface region formed therebetween. The number of side surface regions corresponds to the number N. For the thickness D of the carrier, preferably, 1 mm ≤ D ≤ 12 mm, particularly 2 mm ≤ D ≤ 10 mm, and particularly 3 mm ≤ D ≤ 9 mm apply. For the maximum dimension A of the carrier parallel to the upper surface and / or the lower surface, preferably, 15 mm ≤ A ≤ 200 mm, particularly 25 mm ≤ A ≤ 150 mm, and particularly 35 mm ≤ A ≤ 100 mm apply.

[0013] The coil module according to claim 5 ensures easy and flexible manufacturing of an efficient coil assembly. The carrier preferably has an upper surface and a lower surface, and a side surface region is arranged therebetween. The number of side surface regions corresponds to the number N. Due to the formation of the side surface regions, the carriers of the coil module can be arranged directly adjacent to each other for manufacturing the coil assembly. In particular, the carriers can be arranged end to end.

[0014] Claim 1The coil module according to [description] ensures simple and flexible production of an efficient coil assembly. By having at least two of the side regions each have their own fastening element, the carrier can be connected to a further carrier of an adjacent coil module. Preferably, the fastening element serves for a form-fit and / or friction-lock and / or materially bonded connection. Preferably, the carrier has at least one first fastening element and at least one second fastening element formed differently from one another. Preferably, each second fastening element is formed negatively (opposite shape) with respect to each first fastening element. Thereby, the first fastening element of one carrier can be connected to the second fastening element of a further carrier, and vice versa. Thereby, the coil modules can be simply and flexibly connected to form a coil assembly.

[0015] Claim 6 The coil module according to [description] ensures simple and flexible production of an efficient coil assembly. The carrier comprises at least one first fastening element and at least one second fastening element, which are formed differently. The fastening elements function for a form-fit and / or friction-lock and / or materially bonded connection to the fastening elements of a further carrier. The second fastening element is preferably formed negatively (in opposite shape) with respect to the first fastening element. Thereby, a form-fit and / or friction-lock and / or materially bonded connection from the first fastening element of the first carrier to the second fastening element of the second carrier becomes possible, and vice versa. Preferably, the first and second fastening elements are arranged alternately in the circumferential direction in the side region. The fastening elements enable simple and flexible connection of the coil modules for constructing a coil assembly.

[0016] Claim 7The coil module described in [[ID=]] enables simple and flexible manufacturing of an efficient coil assembly. Preferably, the coil is wound in a spiral or helical shape. In particular, a spiral shape means that the distance from the winding axis at the outer end of the winding is greater than the distance from the winding axis at the inner starting end of the winding. Preferably, all windings of the coil are in one plane. Preferably, the coil is arranged on the upper surface of the carrier. Preferably, at least one winding, in particular each winding, forms n (where n = N) straight winding portions. For example, when the carrier is formed in an octagonal shape, each winding of the coil is preferably wound in an octagonal spiral shape. Preferably, the straight winding portions are arranged parallel to the straight and / or planar side regions of the carrier or the sides of the polygonal basic shape.

[0017] Claim 8 The coil module described in [[ID=]] enables simple and flexible manufacturing of an efficient coil assembly. By the design of at least one winding, preferably each winding, the surface area provided by the carrier for arranging the coil is optimally utilized. The straight winding portions of each winding are arranged, in particular, parallel to the straight and / or planar side regions of the carrier or the sides of the polygonal basic shape. The coil is preferably polygonal and wound in a spiral shape.

[0018] Claim 9The coil module described in enables simple and flexible manufacturing of an efficient coil assembly. At least one spacer element enables a mechanically and / or electrically separated or insulated assembly of adjacent windings of the coil. Preferably, at least one spacer element is made of a magnetic material, in particular a ferrite material. For example, at least one spacer element is made of a ferrite material. In particular, at least one spacer element reduces the proximity effect, thereby better utilizing the conductor cross-section of the coil and improving the coupling in wireless electromagnetic energy transmission. At least one spacer element is formed, for example, as a ferrite foil. The ferrite foil preferably has a thickness between 50 μm and 200 μm. The height of at least one spacer element substantially corresponds to the height of the coil. Preferably, at least one spacer element is integrally formed with the carrier and / or is part of the carrier.

[0019] A further object of the present invention is to provide a coil assembly that supplies efficient wireless electromagnetic power transmission in a simple and flexible manner for various applications.

[0020] This object is achieved Claim 10 by a coil assembly having the characteristics of . Preferably, the coil assembly has K coil modules, where 2 ≤ K ≤ 100, in particular 6 ≤ K ≤ 80, and in particular 10 ≤ K ≤ 60. Preferably, in the case of adjacent coil modules, the carriers are mechanically connected to each other and / or the coils are electrically connected to each other. Preferably, the coils of a plurality of coil modules are connected in series and / or in parallel. The coil assembly is composed of, for example, figure-eight shaped coil modules.

[0021] The present invention is further based on the object of providing a method for simply and flexibly manufacturing an efficient coil assembly for wireless electromagnetic energy transmission.

[0022] This object is achieved Claim 11It is achieved by a method having the features described in. The advantages of the method according to the present invention correspond to the advantages of the coil module and the coil assembly according to the present invention already described.

[0023] Further features, advantages and details will become apparent from the description of the following embodiments. becomes

Brief Description of the Drawings

[0024] [Figure 1] It is a perspective view of a coil assembly composed of a plurality of coil modules according to the first embodiment. [Figure 2] It is a plan view of the lower side of the coil assembly of FIG. 1. [Figure 3] It is a perspective view of a coil module according to the second embodiment. [Figure 4] It is a perspective view of a coil module according to the third embodiment.

Modes for Carrying Out the Invention

[0025] Hereinafter, a first embodiment of the present invention will be described with reference to FIGS. 1 and 2. The coil assembly 1 is composed of a plurality of coil modules M, and in FIG. 1, M 1 , M 2 , M 3 are individually designated. The coil modules M 1 , M 2 , and M 3 are formed identically. Hereinafter, as long as the distinction between the coil modules M 1 , M 2 , and M 3 is not important, they are generally referred to as the coil module M. As long as the distinction is important hereinafter, the coil modules are designated as M 1 , M 2 , and M 3 .

[0026] The following will describe in detail one of the coil modules M. The coil module M is composed of a carrier 2 on which a coil 3 is disposed. The carrier 2 has a polygonal basic shape P having a number of N corners. The corners are individually specified from p 1 to p N . In this embodiment, N = 8. Therefore, the polygonal basic shape P is an octagon.

[0027] The polygonal basic shape P has an axis R. It is rotationally symmetric about the axis R at an angle α = 360°·2 / N = 90°. The polygonal basic shape P has equal interior angles β. The polygonal basic shape P has a first side length L 1 for the first side and a second side length L 2 for the second side. The first side length L 1 is larger than the second side length L 2 . The sides with different side lengths L 1 and L 2 are alternately arranged in one direction about the axis R.

[0028] The carrier 2 is configured in a plate shape. The carrier 2 is composed of a base plate G having an upper surface S O , a lower surface S U , and side surface regions S 1 to S N disposed therebetween. In this embodiment, the carrier 2 has eight side surface regions S 1 to S 8 . The side surface regions S 1 to S 8 are configured to be straight and planar. The carrier 2 is provided with a first fastening element B 1 and a second fastening element B 2 in the side surface regions S 1 to S 8 . The first fastening element B 1 is disposed in the side surface regions S 1 , S 3 , S 5 , and S 7 , while the second fastening element B 2 is disposed in the side surface regions S 2 , S 4 , S 6 , and S8 is arranged at 1 and B 2 are formed in different ways. Fastening element B 1 is formed as a dovetail-shaped protrusion, while the second fastening element B 2 is formed as a dovetail-shaped recess. The second fastening element B 2 has a negative (exactly opposite) shape with respect to the first fastening element B 1 . Fastening element B 1 and B 2 are integrally formed with the base plate G of the carrier 2. Fastening element B 1 and B 2 are oriented so that they are connected by translation parallel to the axis R.

[0029] The carrier 2 is made of a magnetic material, preferably a ferrite material. The ferrite material consists in particular of manganese and zinc. The carrier 2 has a thickness D in the direction of the axis R. For the thickness D, 1 mm ≤ D ≤ 12 mm applies. The carrier 2 has a maximum dimension A perpendicular to the axis R. For the maximum dimension A, 15 mm ≤ A ≤ 200 mm applies.

[0030] The carrier 2 comprises an outer frame 4 arranged on the upper surface S O . This outer frame 4 is integrally formed with the base plate G. Thus, the outer frame 4 is made of a magnetic material, for example a ferrite material. The frame 4 is formed according to a polygonal basic shape P and is formed so as to be open in the side surface region S 1 .

[0031] The coil 3 is arranged inside the outer frame 4. The coil 3 is wound spirally around the axis R. The coil 3 basically has three windings, which are individually designated as W 1 , W 2 , W 3 . The windings from W 1 to W 3 are arranged in one common plane. The cross-sectional area of the coil 3 is preferably between 1 mm 2 and 10 mm 2 .

[0032] Winding W 1 from W 3 each of which is wound polygonal so that the winding W 1 from W 3 forms n straight winding portions w. Hereinafter, let n = N. This means that the winding W 1 from W 3 has a polygonal shape corresponding to the polygonal basic shape P. The winding portion w extends parallel to the side surface region S 1 from S 8 or extends parallel to the side surface of the polygonal basic shape P. The coil 3 includes an inner terminal A 1 and an outer terminal A 2 The inner terminal A 1 is connected to the winding W 1 and is led to the outside below the winding W 2 W 3 and the outer terminal A 2 The outer terminal A 2 is connected to the winding W 3 The terminals A 1 and A 2 are arranged in the side surface region S.

[0033] The carrier 2 further includes an inner frame 5 disposed on the side facing the axis R of the coil 3. The inner frame 5 is integrally formed with the base plate G. Therefore, the inner frame 5 is formed of a magnetic material, for example, a ferrite material. The inner frame 5 has a polygonal shape corresponding to the polygonal basic shape P. The side surface of the inner frame 5 extends parallel to the side surface of the outer frame 4. The inner frame 5 is formed to open toward the side surface region S 1 toward

[0034] Winding W 1 W 2 between, and winding W 2 W 3Between them, one spacer element 6 and 7 are respectively arranged. The spacer elements 6 and 7 are integrally formed with the base plate G and become part of the carrier 2. Therefore, the spacer elements 6 and 7 are formed of a magnetic material, for example, a ferrite material. The frames 4 and 5 are thus formed of a magnetic material, for example, a ferrite material. The spacer elements 6 and 7 have a polygonal shape corresponding to the winding W 1 from W 3 to W. The spacer elements 6 and 7 are formed to open towards the side surface region S 1 .

[0035] To manufacture the coil assembly 1, the coil modules M 1 , M 2 , and M 3 are mechanically connected. For this purpose, the coil module M 2 is connected by the first fastening element B 1 to the second fastening element B 1 of the coil module M 2 . Further, the coil module M 2 is connected by the first fastening element B 1 to the second fastening element B 3 of the coil module M 2 . As a result, the coil assembly 1 becomes a square shape. By further connecting the coil modules M in a corresponding manner, the coil assembly 1 can be formed into a desired shape according to the application, for example, a figure-eight shape.

[0036] The coil modules M 1 , M 2 , and M 3 are further electrically connected to each other. The coils 3 of the coil modules M 1 , M 2 , and M 3 are connected in series, and currents can flow in the same direction in each mechanical connection region through the coils 3 of the adjacent coil modules M 1 , M 2 and the coils 3 of the adjacent coil modules M 2 , M 3 . For this reason, the coil module M1 Terminal A 2 is connected to the terminal A of the coil module M 2 Terminal A 2 is connected to the coil module M 2 Terminal A 1 is connected to the terminal A of the coil module M 3 Terminal A 1 is connected thereto. In FIG. 1, the current I is illustrated by a dashed line and an arrow.

[0037] Due to the fact that the coil module M can be connected in a simple and flexible manner to form the coil assembly 1, the coil assembly 1 has high efficiency in wireless electromagnetic power transmission. The coil module M can be manufactured in a simple and automatic manner.

[0038] Hereinafter, a second embodiment of the present invention will be described with reference to FIG. 3. Different from the first embodiment, the first fastening element B 1 is arranged in the side regions S 2 , S 4 , S 6 , and S 8 , while the second fastening element B 2 is arranged in the side regions S 1 , S 3 , S 5 , and S 7 . The first fastening element B 1 is formed as a dovetail-shaped protrusion arranged on the base plate G, while the second fastening element B 2 is formed as a dovetail-shaped recess. The fastening elements B 1 , B 2 are arranged in such a direction that the mechanical connection of the two coil modules M is performed by a movement parallel to the upper surface S O of the base plate G. Since the side regions S 1 to S 8 have equal lengths L, the polygonal basic shape P is regular. The terminal A 1 is led out externally above the windings W 2 , W 3 . For a further structure and extensive operating modes of the coil module M, the previous embodiments are referred to.

[0039] Hereinafter, a third embodiment of the present invention will be described with reference to FIG. 4. Different from the previous embodiments, the first fastening element B 1 is formed as a protrusion arranged at the lower part, while the second fastening element B 2 is formed as a protrusion arranged at the upper part. Also, the first fastening element B 1 is arranged in the lateral direction of the base plate G, whereas the second fastening element B 2 is arranged on the upper surface S O of the base plate G and in the outer frame 4, and extends laterally outward. The outer frame 4 is formed so as to be open or interrupted in the side surface regions S 1 , S 3 , S 5 , S 7 . For mechanical connection, the first fastening element B 1 and the second fastening element B 2 of adjacent coil modules M are arranged vertically so as to overlap. In the overlapping region, the fastening elements B 1 and B 2 are connected to each other. This connection can be made, for example, by material bonding with an adhesive and / or by a form fit via profiles and counter-profiles. For the further structure and further operating mode of the coil module M, the previous embodiments are referred to.

Explanation of Reference Numerals

[0040] 1 Coil assembly 2 Carrier 3 Coil 4 Outer frame 5 Inner frame 6, 7 Spacer element A 1 Inner terminal A 2 Outer terminal B 1 First fastening element B 2 Second fastening element G Base plate I Current M, M 1, M 2 , M 3 Coil module P polygonal basic shape R axis S, S 1 , S 2 , S 3 , S 4 , S 5 , S 6 , S 7 , S 8 Side region S O Upper surface S U Lower surface W 1 , W 2 , W 3 Winding w Winding part α Angle β Interior angle

Claims

1. N corners (P １ ~P Ｎ : Here, 4 ≤ N ≤ 12), having a polygonal basic shape (P) and composed of a magnetic material, a carrier (2), wherein the polygonal basic shape (P) is rotationally symmetric at an angle of 360°·2 / N, the carrier (2) and, A coil (3) disposed on the carrier (2), In a coil module for manufacturing a coil assembly comprising The carrier (2) has side regions (S1 to SN), and each fastening element (B1, B2) is arranged in at least two of the side regions (S1 to SN), characterized in that, Coil module.

2. The N corners (P １ ~P Ｎ ) are even in number, and the coil module according to claim 1 is characterized by this.

3. The coil module according to claim 1 or 2, characterized in that the polygonal basic shape (P) is rotationally symmetric at an angle of 360° / N.

4. The coil module according to any one of claims 1 to 3, characterized in that the carrier is plate-shaped.

5. The carrier (2) has at least partially linear and / or planar side regions (S １ ~S Ｎ ), and is characterized by the coil module according to any one of claims 1 to 4.

6. At least two different fastening elements (B １ , B ２ ) are arranged in the side region (S １ ~S Ｎ ), characterized in that the coil module according to any one of claims 1 to 5.

7. The coil (3) includes at least two windings (W １ ~W ３ ) arranged on one plane, and the coil module according to any one of claims 1 to 6 is characterized in that.

8. The coil (3) includes at least one winding (W １ ~W ３ ) that forms n linear winding portions (w), where n = N, and is characterized in that it is the coil module according to any one of claims 1 to 7.

9. In particular, at least one spacer element (6, 7) made of a magnetic material is disposed between two adjacent windings (W １ ~W ３ ) of the coil (3), and the coil module according to any one of claims 1 to 8 is characterized in that.

10. Having at least two coil modules (M) according to any one of claims 1 to 9, wherein the coils (3) of the coil modules are electrically connected and / or the carriers (2) of the coil modules are mechanically connected. Coil assembly for wireless electromagnetic energy transmission.

11. A method for manufacturing a coil assembly, comprising: Providing at least two coil modules (M) according to any one of claims 1 to 9; Electrically connecting the coils (3) of the at least two coil modules (M) and / or mechanically connecting the carriers (2) of the at least two coil modules (M).

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