Wireless power transmission device including cooling mechanism and manufacturing method thereof

Abstract

This wireless power transmission pad device comprises: a dielectric core which provides a magnetic path for a magnetic flux; a coil which provides a path through which a current associated with the magnetic flux flows; a cooling unit which provides a water path for cooling water for at least partially receiving heat generated from at least one of the dielectric core or the coil and then discharging the heat to the outside; and a filling member which is at least partially filled in the wireless power transmission pad device and is formed to be in close contact with the dielectric core or the coil, so that heat conduction from at least one of the dielectric core or the coil to the cooling unit is smoothly performed.

Description

Wireless power transmission device including cooling mechanism and manufacturing method thereof

[0001] Exemplary embodiments relate to an electrical device including a cooling mechanism, and more particularly, to an electrical device including a water-cooled cooling device, and to a wireless power transfer apparatus including a cooling mechanism and a manufacturing method thereof {Wireless Power Transfer Apparatus Employing Cooling Arrangement and Manufacturing Method thereof}.

[0002] Electric vehicles (EVs) are propelled by a motor powered by battery power, and have the advantages of producing fewer air pollutants such as exhaust gases and noise, being less prone to breakdowns, having a longer lifespan, and being simple to operate compared to conventional gasoline engine vehicles.

[0003] Electric vehicles can be categorized into several types based on their propulsion system. Specifically, electric vehicles include hybrid electric vehicles (HEVs), which in turn include plug-in hybrid electric vehicles (PHEVs). HEVs derive their primary energy from an internal combustion engine and supplement it with auxiliary energy from a battery-powered motor. The HEV's battery can be charged, for example, by energy recovered during regenerative braking. PHEVs, like pure electric vehicles, can be charged using power supplied from an external charger.

[0004] An electric vehicle charging system can be defined as a system that charges the batteries mounted on an electric vehicle using power from the commercial grid or an energy storage device. Electric vehicle charging systems may include conductive charging systems using cables and contactless wireless power transfer systems.

[0005] When charging via wireless power transfer, the electric vehicle is positioned and aligned to a charging spot using low frequency (LF) signals, low power excitation (LPE) signals, or received signal strength indication (RSSI), and then power is supplied from the supply device via magnetic induction or magnetic resonance. The International Organization for Standardization (ISO) has completed standardization of the 'Vehicle to grid communication interface' with the ISO 15118 series, and the International Electrotechnical Commission (IEC) is standardizing the WTP system with the IEC 61980 series. The Society of Automotive Engineers (SAE International) has established the SAE J2954 standard, an industry standard for the specifications required for wireless power transfer and positioning for lightweight plug-in electric vehicles.

[0006] Meanwhile, during the charging process using wireless power transfer, heat is generated on both the transmitting and receiving sides of the wireless power transfer device. This heat generation can be more severe on the receiving side than on the transmitting side, and the amount of heat generated is known to increase when the alignment between the transmitting and receiving coils is imperfect. Heat generation on the receiving side leads to energy waste, lowering charging efficiency and increasing the temperature of the wireless power transfer device within the vehicle.

[0007] Overheating due to temperature rise can damage or shorten the lifespan of charging-related components, and can even lead to fire or larger-scale disasters. Considering these issues, the charging process may need to be interrupted or the charging speed reduced, and the target state of charge (TSO) may need to be set lower. Ultimately, temperature rise in wireless power transfer devices can degrade their stability, reliability, and operating efficiency. Therefore, a mechanism for cooling wireless power transfer devices during the charging process is necessary. However, relevant standards, including ISO 15118, IEC 61980, and SAE J2954 mentioned above, do not provide any provisions for this.

[0008] Exemplary embodiments provide a wireless power transmission device capable of effectively discharging heat generated during an electric vehicle charging process using wireless power transmission to the outside.

[0009] Exemplary embodiments provide a method of manufacturing such a wireless power transmission device.

[0010] According to one aspect of an exemplary embodiment, a wireless power transmission pad device includes a dielectric core providing a magnetic path for magnetic flux; a coil providing a path for a current associated with the magnetic flux to flow; a cooling unit providing a water path for cooling water to at least partially receive heat generated from at least one of the dielectric core or the coil and release it to the outside; and a filling member that is at least partially filled inside the wireless power transmission pad device and is formed to be in close contact with the dielectric core or the coil so as to facilitate heat conduction from at least one of the dielectric core or the coil to the cooling unit.

[0011] The above wireless power transmission pad device may be a receiving pad device. In this case, the magnetic flux may be generated from an external transmitting pad, and the coil may be a receiving coil that provides a path for an induced current induced from the magnetic flux to flow.

[0012] The wireless power transmission pad device may further include a core guide for preventing the flow of the dielectric core and a coil guide for fixing the coil.

[0013] Each of the core guide and the coil guide may have a plurality of vertical through holes formed therein so that the filling material can be filled therein.

[0014] The wireless power transmission pad device may further include a film disposed between the dielectric core and the coil to prevent direct contact between the dielectric core and the coil. In this case, the film may also have a plurality of through holes formed at positions corresponding to the plurality of vertical through holes formed in the core guide and the coil guide.

[0015] The cooling unit may include a cooling unit housing that is arranged to contact the filling member and includes the water channel formed by being recessed from the upper surface, and has an inlet and an outlet for the water channel; and a housing cover that is arranged on the upper portion of the cooling unit housing and seals the water channel from above.

[0016] The water channel of the cooling unit housing may be open toward the direction in which the housing cover is arranged, and a protrusion corresponding to the water channel may be formed on a surface of the housing cover facing the water channel so as to cover and seal the water channel.

[0017] On the bottom surface of the above water channel, a plurality of vertical protrusions may be formed to protrude upward so as to guide the flow direction of the cooling water and increase the heat transfer area of ​​the cooling water channel.

[0018] The cooling unit may include a plurality of sides, and the bottom surface of the water channel may be higher than the lower ends of the plurality of sides, so that a receiving space may be formed on the inner side toward the center of the plurality of sides. In this case, the dielectric core, the coil, and the filling member may be received in the receiving space.

[0019] The wireless power transmission pad device may further include a base cover that supports the wireless power transmission pad device on the opposite side of the cooling unit. In this case, the base cover and the cooling unit may be fastened with screws while the dielectric core, the coil, and the charging member are positioned between the base cover and the cooling unit.

[0020] A method for manufacturing a wireless power transmission pad according to another aspect of an exemplary embodiment comprises the steps of: providing members including a dielectric core providing a magnetic path for magnetic flux and a coil providing a path for a current associated with the magnetic flux to flow; forming a coil subassembly by injecting a predetermined filler into a space between the members and solidifying the filler to form the filler member; and fixing a cooling unit to the coil subassembly, the cooling unit providing a water channel for cooling water to at least partially receive and dissipate heat generated from at least one of the dielectric core or the coil to the outside.

[0021] The above wireless power transmission pad device may be a receiving pad device. In this case, the magnetic flux may be generated from an external transmitting pad, and the coil may be a receiving coil that provides a path for an induced current induced from the magnetic flux to flow.

[0022] The step of forming the above-mentioned filling member may include a step of fastening the above-mentioned members including the dielectric core and the coil; and a step of forming the filling member by injecting and solidifying the above-mentioned filling material.

[0023] The step of securing the cooling unit to the coil subassembly may include the steps of arranging the coil subassembly and the cooling unit on a base cover, and fastening the base cover, the coil subassembly, and the cooling unit.

[0024] The base cover, the coil subassembly, and the cooling unit can be fastened using screws made of peak material.

[0025] The above-described members may further include a core guide for preventing movement of the dielectric core; a coil guide for fixing the coil; and a film disposed between the dielectric core and the coil to prevent direct contact between the dielectric core and the coil. In this case, a plurality of through holes may be formed in each of the core guide, the coil guide, and the film so that the filling member can be filled therein.

[0026] The step of securing the cooling unit to the coil subassembly may include the steps of: arranging a cooling unit housing, which includes the water channel formed by recessing from an upper surface and has an inlet and an outlet for the water channel, so as to be in contact with the filling member; arranging a housing cover on an upper portion of the cooling unit housing that seals the water channel from above; and fastening the coil subassembly, the cooling unit housing, and the housing cover.

[0027] The water channel of the cooling unit housing may be open toward the direction in which the housing cover is arranged, and a protrusion corresponding to the water channel may be formed on a surface of the housing cover facing the water channel so as to cover and seal the water channel. A plurality of vertical protrusions may be formed on the bottom surface of the water channel so as to protrude upward so as to guide the flow direction of the cooling water and increase the heat transfer area of ​​the cooling water channel.

[0028] The cooling unit may include a plurality of side surfaces, and the bottom surface of the water channel may be higher than the lower ends of the plurality of side surfaces, so that an accommodation space may be formed on the inner side toward the center of the plurality of side surfaces. In this case, the step of fixing the cooling unit to the coil subassembly may include the step of placing the coil subassembly and the cooling unit on a base plate while the coil subassembly is inserted into the accommodation space; and the step of fastening the base plate and the cooling unit.

[0029] According to an exemplary embodiment, heat generated during the charging process via wireless power transfer can be effectively dissipated to the outside. Consequently, heat generated during the charging process does not accumulate within the wireless power transfer device, suppressing temperature increases within the wireless power transfer device and enabling stable, uninterrupted charging. Consequently, damage or reduced lifespan of charging-related components due to heat generation is prevented, and fires and larger-scale disasters can be prevented.

[0030] Therefore, the exemplary embodiment can improve the stability and reliability of wireless charging and enhance charging efficiency.

[0031] FIG. 1 is a conceptual diagram for explaining the concept of wireless power transmission for an electric vehicle according to an exemplary embodiment of the present invention.

[0032] FIG. 2 is a block diagram of a wireless power transmission system according to an exemplary embodiment of the present invention.

[0033] FIG. 3 is a perspective view of a receiving pad device according to an exemplary embodiment of the present invention.

[0034] Figure 4 is a plan view of a receiving pad device according to an exemplary embodiment of the present invention.

[0035] Figure 5 is an exploded perspective view of a receiving pad device according to an exemplary embodiment of the present invention.

[0036] Fig. 6a is a cross-sectional view taken along line AA of the receiving pad device illustrated in Fig. 3.

[0037] Fig. 6b is a cross-sectional view taken along line BB of the receiving pad device illustrated in Fig. 3.

[0038] Figure 7 is a plan view of a lower cover according to an exemplary embodiment of the present invention.

[0039] Figure 8 is a plan view of a coil according to an exemplary embodiment of the present invention.

[0040] Figure 9 is a perspective view of a coil guide according to an exemplary embodiment of the present invention.

[0041] Figure 10 is a plan view of a film according to an exemplary embodiment of the present invention.

[0042] FIG. 11 is a perspective view of a dielectric core according to an exemplary embodiment of the present invention.

[0043] FIG. 12 is a bottom view of a core guide according to an exemplary embodiment of the present invention.

[0044] FIG. 13a is a perspective view of a cooling unit housing according to an exemplary embodiment of the present invention.

[0045] Figure 13b is a plan view of the cooling unit housing illustrated in Figure 13a.

[0046] FIG. 13c is a drawing showing an example of a flow path of coolant in the cooling unit housing illustrated in FIG. 13a.

[0047] FIG. 14a is a perspective view from below the side of a housing cover according to an exemplary embodiment of the present invention.

[0048] Figure 14b is a plan view of the housing cover illustrated in Figure 14a.

[0049] Figure 14c is a bottom view of the housing cover illustrated in Figure 14a.

[0050] Figure 15 is a flowchart showing an assembly process of a receiving pad device according to an exemplary embodiment of the present invention.

[0051] Figure 16 is a block diagram of a cooling system according to an exemplary embodiment of the present invention.

[0052] FIG. 17 is a block diagram of a cooling system according to another exemplary embodiment of the present invention.

[0053] FIGS. 18a and 18b are diagrams showing the configuration of a device used for performance testing of a receiving pad device according to an exemplary embodiment.

[0054] The present invention is susceptible to various modifications and embodiments. Specific embodiments are illustrated in the drawings and described in detail in the detailed description. However, this is not intended to limit the present invention to specific embodiments, but rather to encompass all modifications, equivalents, and alternatives falling within the spirit and technical scope of the present invention.

[0055] While ordinal numbers such as "first," "second," etc. may be used to describe various components, these components should not be limited by these terms. These terms are used solely to distinguish one component from another. For example, a first component could be referred to as a "second component," and similarly, a second component could also be referred to as a "first component," without departing from the scope of the present invention. The term "and / or" includes any combination of multiple related listed items or any one of multiple related listed items.

[0056] In the embodiments of the present application, “at least one of A and B” may mean “at least one of A or B” or “at least one of combinations of one or more of A and B.” Furthermore, in the embodiments of the present application, “at least one of A and B” may mean “at least one of A or B” or “at least one of combinations of one or more of A and B.”

[0057] When a component is referred to as being "connected" or "connected" to another component, it should be understood that it may be directly connected or connected to that other component, but that there may be other components intervening. Conversely, when a component is referred to as being "directly connected" or "connected" to another component, it should be understood that there are no other components intervening.

[0058] The terminology used in this application is only used to describe specific embodiments and is not intended to limit the present invention. The singular expression includes the plural expression unless the context clearly indicates otherwise. In this application, it should be understood that the terms "comprise" or "have" indicate the presence of a feature, number, step, operation, component, part, or combination thereof described in the specification, but do not exclude in advance the possibility of the presence or addition of one or more other features, numbers, steps, operations, components, parts, or combinations thereof.

[0059] Unless otherwise defined, all terms used herein, including technical or scientific terms, have the same meaning as commonly understood by one of ordinary skill in the art to which this invention pertains. Terms defined in commonly used dictionaries should be interpreted as having a meaning consistent with their meaning in the context of the relevant technology, and shall not be interpreted in an idealized or overly formal sense unless explicitly defined herein.

[0060] Some terms used in this specification are defined as follows:

[0061] An electric vehicle (EV) may refer to an automobile, as defined in 49 CFR (Code of Federal Regulations) 523.3, etc. An EV is capable of highway use and can be powered by electricity supplied by an onboard energy storage device, such as a rechargeable battery, from an external power source. Power sources may include residential or public power services, or a generator powered by onboard fuel.

[0062] Electric vehicles can be referred to as electric cars, electric automobiles, electric road vehicles (ERVs), plug-in vehicles (PVs), and plug-in vehicles (xEVs), while xEVs can be referred to as or categorized as plug-in all-electric vehicles (BEVs) or battery electric vehicles (PEVs), hybrid electric vehicles (HEVs), hybrid plug-in electric vehicles (HEVs), and plug-in hybrid electric vehicles (PHEVs).

[0063] A wireless power charging system (WCS) may refer to a system for controlling the interaction between a ground assembly (GA) and a vehicle assembly (VA) or a primary device and a secondary device, including wireless power transfer and alignment and communication.

[0064] Wireless power transfer (WPT) can refer to the transfer of power from an alternating current (AC) power supply network, such as a utility or grid, to an electric vehicle through contactless means.

[0065] Heavy duty vehicles (HD Vehicles) may refer to any vehicle with four or more wheels as defined in 49 CFR 523.6 or CFR 37.3 (bus).

[0066] A light-duty plug-in electric vehicle (LDEV) may refer to a vehicle with three or four wheels that is propelled by an electric motor powered by a rechargeable battery or other energy source, primarily intended for use on public streets, roads, and highways. A LEV may be defined as having a gross weight of less than 4.545 kg.

[0067] A wireless power charging system (WCS) may refer to a system for controlling between a Supply Device (or Ground Assembly, GA) and an EV device (or Vehicle Assembly, VA), including wireless power transfer, alignment, and communication.

[0068] Wireless power transfer (WPT) can refer to the transfer of electrical power from an alternating current (AC) power supply network, such as a utility or grid, to an electric vehicle through contactless means.

[0069] A utility provides electrical energy and can be defined as a collection of systems, typically including a Customer Information System (CIS), Advanced Metering Infrastructure (AMI), and a Rates and Revenue system. Utilities enable plug-in electric vehicles to access energy through price lists or discrete events. Utilities can also provide information on tariffs, metered power consumption intervals, and EV program qualifications for plug-in electric vehicles.

[0070] Smart charging can be described as a system where EVSE and / or electric vehicles (including plug-in hybrid electric vehicles) communicate with the power grid to optimize vehicle charge or discharge rates to grid capacity or time of day for cost-to-use ratios.

[0071] Interoperability can refer to the state in which components of a system can work together to achieve the intended function of the entire system. Information interoperability can refer to the ability of two or more networks, systems, devices, applications, or components to share information securely and effectively and easily with little or no user inconvenience.

[0072] An inductive charging system can refer to a system that electromagnetically transfers energy in the forward direction from the power supply network to an electric vehicle via a loosely coupled transformer. In this embodiment, the inductive charging system can correspond to an electric vehicle charging system.

[0073] An inductive coupler can refer to a transformer formed by a GA coil and a VA coil, which transmits power through electrical insulation.

[0074] Inductive coupling can refer to the magnetic coupling between two coils. The two coils can refer to the ground assembly coil and the vehicle assembly coil.

[0075] A supply power circuit (SPC) / ground assembly (GA) may refer to an assembly disposed on the primary / ground assembly or infrastructure side, including a primary coil / GA coil and other suitable components. The other suitable components may include at least one component for controlling impedance and resonant frequency, ferrite for reinforcing a magnetic path, and electromagnetic shielding materials. For example, the SPC or GA may include a power / frequency conversion device necessary to function as a power source of a wireless charging system, an SPC controller / GA controller, and wiring from the grid, and wiring between each unit and filtering circuits, a housing, etc.

[0076] An EV power circuit (EVPC) / vehicle assembly (VA) may refer to an assembly placed in a vehicle, including a secondary coil / VA coil and other suitable components. The other suitable components may include at least one component for controlling impedance and resonant frequency, ferrite for reinforcing the magnetic path, and electromagnetic shielding materials. For example, an EVPC or VA may include a rectifier / power converter necessary to function as a vehicle component of a wireless charging system, an EVPC controller / VA controller, and wiring for a vehicle battery, as well as wiring between each unit and filtering circuits, a housing, etc.

[0077] The aforementioned SPC may be referred to or distinguished as a ground assembly (GA), etc., and similarly, the EVPC may be referred to or distinguished as a vehicle assembly (VA), etc.

[0078] The aforementioned GA may be referred to as a primary device (PD), a primary device, etc., and similarly, the VA may be referred to as a secondary device (SD), a secondary device, etc.

[0079] The aforementioned GA may be referred to as a supply device, a power supply-side device, etc., and similarly, the VA may be referred to as an electric vehicle device (EV device), an electric vehicle-side device, etc.

[0080] A primary device may be a device external to the electric vehicle that provides contactless coupling to the secondary device. The primary device may be referred to as a primary-side device. When the electric vehicle receives power, the primary device may act as a power source that transmits power. The primary device may include a housing and all covers.

[0081] A secondary device may be a device mounted on an electric vehicle that provides contactless coupling to the primary device. The secondary device may be referred to as a secondary device. When the electric vehicle receives power, the secondary device can transfer power from the primary device to the electric vehicle. The secondary device may include a housing and all covers.

[0082] The supply power electronics may be part of the SPC or GA that regulates the output power level to the primary coil / GA coil based on information from the vehicle. The EV power electronics may be part of the EVPC or VA that monitors certain vehicle parameters during charging and initiates communication with the SPC or GA to control the output power level.

[0083] The supply power electronics described above may be referred to as ground assembly electronics (GA electronics), a ground assembly controller (GA controller), or a primary device communication controller (PDCC), and the electric vehicle power electronics (EV power electronics) may be referred to as vehicle assembly electronics (VA electronics), a vehicle assembly controller (VA controller), or an electric vehicle communication controller (VA controller).

[0084] The magnetic gap may refer to the vertical distance between the highest plane of the upper portion of the litz wire or the upper portion of the magnetic material of the primary coil / GA coil and the lowest plane of the lower portion of the litz wire or the magnetic material of the secondary coil / VA coil when they are aligned with each other.

[0085] Ambient temperature may refer to the ground level temperature measured in the atmosphere of a target subsystem that is not directly exposed to sunlight.

[0086] Vehicle ground clearance can refer to the vertical distance between the road or pavement and the lowest part of the vehicle's floor pan.

[0087] Vehicle magnetic ground clearance may refer to the vertical distance between the lowest plane of the floor of the Litz wire or the insulating material of the secondary coil / VA coil mounted on the vehicle and the road pavement.

[0088] Secondary coil surface distance / Vehicle assembly (VA) coil surface distance may refer to the vertical distance between the bottommost plane of the Litz wire or the magnetic material of the secondary coil / VA coil and the lowest outer surface of the secondary coil / VA coil. This distance may include additional items packaged with protective covering material and coil packaging material.

[0089] The secondary coil described above may be referred to as a VA coil, a vehicle coil, a receiver coil, etc., and similarly, the primary coil may be referred to as a ground assembly coil (GA coil), a transmit coil, etc.

[0090] Alignment may refer to the process of aligning the relative positions of a secondary device with respect to a primary device for a specified, efficient power transfer. In this specification, alignment may refer to, but is not limited to, the positional alignment of a wireless power transfer system.

[0091] Pairing may refer to the process of associating a vehicle (electric vehicle) with a single dedicated ground assembly (power supply side device) configured to transmit power. In this specification, pairing may include the process of associating a charging spot or a specific ground assembly with a vehicle assembly controller. Correlation / Association may include the process of establishing a relationship between two peer communication entities.

[0092] Correlation / Association may include the process of establishing a relationship between two peer communication entities.

[0093] Hereinafter, preferred embodiments of the present invention will be described in detail with reference to the attached drawings. In order to facilitate an overall understanding in describing the present invention, identical reference numerals are used for identical components in the drawings, and redundant descriptions of identical components are omitted.

[0094] Figure 1 is a conceptual diagram for explaining the concept of wireless power transmission for an electric vehicle to which one embodiment of the present invention is applied.

[0095] Wireless power transfer can be utilized to transfer power from a charging station to an electric vehicle (20) in order to charge the battery of the electric vehicle (20). Here, wireless power transfer, for example, magnetic field wireless power transfer (MF-WPT), can be defined as the transfer of energy through a magnetic field between an electric vehicle power supply unit (EVSE: Electric Vehicle Supply Equipment, 10) of a charging station and an electric vehicle (20) without current flow through a galvanic connection by a conductor.

[0096] The EVSE (10) can receive power from a commercial power grid (2) or a power backbone, and supply energy to the electric vehicle (20) through a transmission pad (11). The transmission pad (11) can include a transmission coil. The electric vehicle (20) can include a reception pad (21) including a reception coil. The transmission coil in the transmission pad (11) can generate magnetic flux and supply magnetic energy to the electric vehicle (20) through the magnetic flux, or supply magnetic energy amplified by magnetic resonance to the electric vehicle (20). The charging station or EVSE (10) can be installed in various locations, such as a parking lot attached to the home of an electric vehicle (20) owner, a parking area for charging electric vehicles at a gas station, a parking area of ​​a shopping center or an office building, etc.

[0097] The EVSE (10) can communicate with an infrastructure management system or infrastructure server that manages the power grid (2) through wired or wireless communication. In addition, the EVSE (10) can also perform wireless communication with an electric vehicle (20). Here, the wireless communication may include a wireless local area network (WLAN) based on WiFi according to the IEEE 802.11 protocol. In addition, the wireless communication may further include P2PS communication using a low frequency (LF) magnetic field signal and / or a low power excitation (LPE) magnetic field signal. For example, the EVSE (10) and the electric vehicle (20) can perform processes such as pairing, positioning, identification, authentication, service authorization, and fee payment through WiFi-based communication, and can perform location alignment through P2PS communication. Furthermore, wireless communication between EVSE (10) and electric vehicle (20) may include one or more of various communication methods such as Bluetooth, Zigbee, and cellular.

[0098] An electric vehicle (20) is a vehicle (automobile) that can be driven by an electric motor using electric energy stored in a rechargeable energy storage device such as a battery (22) as a power source. An electric vehicle (20) may include a hybrid vehicle that includes both an electric motor and a general internal combustion engine, and may also include not only automobiles but also motorcycles, carts, scooters, and electric bicycles.

[0099] The electric vehicle (20) may include a receiving pad (21) including a receiving coil for wirelessly receiving magnetic energy from the EVSE (10). The receiving coil in the receiving pad (21) receives magnetic energy from the transmitting coil of the transmitting pad (11) in the charging station (10), for example, through magnetic flux or magnetic resonance. Due to the magnetic energy received from the electric vehicle (20), an electromotive force is induced in the receiving coil of the receiving pad (21) and an induced current flows, and the induced current is rectified into a direct current and then charges the battery (22).

[0100] Figure 2 is a block diagram of a wireless power transmission system according to one embodiment of the present invention. The wireless power transmission system includes an electric vehicle power supply unit (EVSE) 10 installed in a charging station and an EV device (202) installed in an electric vehicle.

[0101] EVSE (10) includes a supply power circuit (SPC: Supply power circuit, 11), a supply equipment communication controller (SECC: Supply equipment communication controller) (14), and a P2PS communication interface (15).

[0102] The supply-side power circuit (11) can receive power from the power grid, form magnetic flux from the power supply, and supply energy to the EV (20) through magnetic resonance. The supply-side power circuit (11) can include a supply-side power electronic circuit (12) and a primary device, i.e., a transmission pad (13).

[0103] The supply-side power electronics circuit (12) receives single-phase or three-phase AC power from the power grid and performs a grid interface function that changes the frequency and voltage level of the input voltage and current. In addition, the supply-side power electronics circuit (12) can perform power factor control, regulation, and filtering operations, and can perform safety measures such as shutdown as needed. In addition, the supply-side power electronics circuit (12) can cause resonance to occur between the transmission pad (13) and the EV device (20) so that high-output energy can be supplied to the EV device (20) through the transmission pad (13). Meanwhile, the supply-side power electronics circuit (12) can compensate for reactance variations for each vehicle and achieve impedance matching. For example, reactance may vary depending on the height difference of the receiving pad (23) and the alignment status in addition to the vehicle-to-vehicle variation, and reactance compensation can reduce the stress on the transmitting coil within the transmitting pad (13) and reduce losses associated with high inverter current and harmonic generation. The supply-side power electronic circuit (12) can control the overall operation of the supply-side power circuit (11) including the transmitting pad (13).

[0104] The transmission pad (13) includes a transmission coil and generates a magnetic field from the supplied power, thereby enabling high-energy level magnetic energy to be transmitted to the EV device (20) through magnetic resonance.

[0105] The supply device communication controller (SECC, 14) is an upper layer controller and can communicate with the EV communication controller (EVCC, 24) in the EV device (20) via a wireless LAN based on, for example, WiFi. The SECC (14) and the EVCC (24) can perform application layer communication of the WPT system according to, for example, the ISO 15118-20 standard, and can perform processes such as pairing, positioning, identification, compatibility verification, authentication, service authorization, and fee payment. The physical layer and data link layer of the WLAN link can be configured to comply with, for example, the ISO 15118-8 standard. In addition, the SECC (14) can control the supply side power circuit (110) to ensure smooth and precise wireless power transmission from the EVSE (10) to the EV device (20). Furthermore, the SECC (14) can control the P2PS communication interface (15).

[0106] The P2PS communication interface (15) performs P2PS communication with the EV device (200) under the control of the SECC (14). In the present specification, including the claims, P2PS communication refers to communication for transmitting and receiving a signal for charging using a low frequency (LF) magnetic field signal and / or a low power magnetic field (LPE) signal. P2PS communication can be used for vehicle positioning and / or position alignment between a transmitting pad (13) and a receiving pad (23).

[0107] Meanwhile, the EV device (20) includes an EV side power circuit (EVPC: EV power circuit, 21), an EV communication controller (EVCC, 24), and a P2PS communication interface (25).

[0108] The EV-side power circuit (21) receives magnetic energy in the form of magnetic flux variation from the supply-side power circuit (11) of the EVSE (10), converts the received magnetic energy into an induced current, and then rectifies the induced current into a direct current to charge the battery (29) in the storage device (28). The EV-side power circuit (21) may include an EV-side power electronic circuit (22) and a secondary device, i.e., a receiving pad (23).

[0109] The receiving pad (23) includes a receiving coil and can receive high-energy level magnetic energy supplied in a magnetic resonance state, for example, by capturing magnetic flux fluctuations induced from the transmitting pad (13).

[0110] The EV-side power electronics circuit (22) receives power from the transmission pad (13) through the reception pad (23) and changes the frequency and voltage level. In addition, the EV-side power electronics circuit (22) can rectify and filter the power received through the reception pad (23). The EV-side power electronics circuit (22) can perform regulation operations and, if necessary, perform safety measures such as shutdown. In addition, the EV-side power electronics circuit (22) can compensate for reactance fluctuations in the reception pad (23) and ensure impedance matching. The supply-side power electronics circuit (12) can control the overall operation of the supply-side power circuit (11) including the transmission pad (13).

[0111] The EV communication controller (EVCC, 24) is an upper layer controller and can communicate with the SECC (14) in the EVSE (10) via a wireless LAN based on, for example, WiFi. The EVCC (24) can perform application layer communication of the WPT system according to, for example, the ISO 15118-20 standard. The physical layer and data link layer of the WLAN link can be configured to comply with, for example, the ISO 15118-8 standard. In addition, the EVCC (24) can control the EV-side power circuit (21) to ensure smooth and precise power reception from the EVSE (10). Furthermore, the EVCC (24) can control the P2PS communication interface (25).

[0112] The P2PS communication interface (25) can perform P2PS communication with the EVSE (20) under the control of the EVCC (24). In the present specification, including the claims, P2PS communication refers to communication that transmits and receives a signal for charging using a low frequency (LF) magnetic field signal and / or a low power magnetic field (LPE) signal. P2PS communication can be used for vehicle positioning and / or position alignment between a transmitting pad (13) and a receiving pad (23).

[0113] According to one embodiment, the P2PS communication interface (15, 25) supports at least one type of P2PS interface among LF signals or LPE signals. Each type of P2PS interface may be a unidirectional P2PS interface. The LF signal is a digitally modulated magnetic field having a frequency belonging to the ultra-low frequency and low frequency (i.e., 3 kHz to 300 kHz, which are LF and VLF bands) among the radio bands defined by the International Telecommunication Union (ITU). In one embodiment, the LF signal may be transmitted by the P2PS communication interface (25) of the EV device (20) and received by the P2PS communication interface (15) of the EVSE (10). For this purpose, the P2PS communication interface (25) of the EV device (20) may include an LF transmitter, and the P2PS communication interface (15) of the EVSE (10) may include an LF receiver. Meanwhile, the LPE signal can be transmitted by the P2PS communication interface (15) of the EVSE (10) and received by the P2PS communication interface (25) of the EV device (20). To this end, the P2PS communication interface (15) of the EVSE (10) can include an LPE transmitter, and the P2PS communication interface (25) of the EV device (20) can include an LPE receiver.

[0114] In an exemplary embodiment of the present invention, the ground assembly (GA) may be used in the same sense as the transmission pad (13). The ground assembly or the transmission pad (13) essentially includes a primary device, i.e., a transmission coil. However, in a modified embodiment, the ground assembly and the transmission pad (13) may be used in different senses. In addition to the transmission coil, the ground assembly or the transmission pad (13) may additionally include at least a portion of an LPE transmitter and / or an LF receiver and / or a supply-side power electronics circuit (12).

[0115] The ground assembly or transmission pad (13) may be installed so as to protrude upward from the ground at the charging spot of the charging station and be at least partially exposed. In another example, the ground assembly or transmission pad (13) may be installed so that the upper surface thereof is an extension of the ground. In another example, the ground assembly or transmission pad (13) may be installed so as to be buried beneath the ground.

[0116] In an exemplary embodiment of the present invention, the vehicle assembly (VA) may be used in the same sense as the receiving pad (23). The vehicle assembly or the receiving pad (23) may include a secondary device, i.e., a receiving coil. However, in a modified embodiment, the vehicle assembly and the receiving pad (23) may be used in different senses. In addition to the receiving coil, the vehicle assembly or the receiving pad (23) may additionally include an LPE receiver and / or an LF transmitter and / or at least a portion of an EV-side power electronics circuit (22). The vehicle assembly or the receiving pad (23) may be installed on the lower part of the vehicle.

[0117] Figures 3 and 4 are a perspective view and a plan view, respectively, of a receiving pad device (23) according to an exemplary embodiment of the present invention. The receiving pad device (23) has a substantially rectangular parallelepiped shape and may include a lower cover (100) located at the bottom, and a cooling unit housing (800) and a housing cover (900) located at the top. A receiving coil is installed inside the receiving pad device (23). An inlet (810) for introducing cooling water and an outlet (820) for discharging cooling water are installed at one side of the cooling unit housing (800). A cooling water pipe can be connected to each of the inlet (810) and the outlet (820) using a push-in fitting, i.e., a so-called 'one-touch fitting'. However, it should be understood that the connection port for connecting the cooling water pipe is not limited to the push-in fitting. Additionally, one side of the receiving pad device (23) includes a pair of lead wires (410, 412) extending from the inside to the outside of the receiving pad device (23).

[0118] Fig. 5 is an exploded perspective view of a receiving pad device (23) according to an exemplary embodiment of the present invention. Fig. 6a is a cross-sectional view taken along line AA of the receiving pad device (23) illustrated in Fig. 3, and Fig. 6b is a cross-sectional view taken along line BB.

[0119] The receiving pad device (23) may include a lower cover (100), a filling member (200), a coil guide (300), a coil (400), a film (500), a dielectric core (600), a core guide (700), a cooling unit housing (800), and a housing cover (900).

[0120] The lower cover (100) supports the durable structure of the receiving pad device (23) from below and protects it from external forces or foreign substances. As illustrated in Fig. 7, the lower cover (100) has a flat plate shape and has a number of screw holes formed on the inner side of the edge. In one embodiment, the lower cover (100) is made of aluminum. However, the present invention is not limited thereto, and the lower cover (100) may also be made of a plastic material.

[0121] The filling member (200) fills the space between at least the coil guide (300) and the core guide (700) within the receiving pad device (23), and transfers heat generated within the receiving pad device (23) to the cooling unit housing (800). Although the filling member (200) is depicted in FIG. 5 as a block-shaped member disposed between the lower cover (100) and the coil guide (300), this is exaggerated for convenience of explanation. In an exemplary embodiment, the filling member (200) may include portions in which the filling material injected into the space between the coil guide (300) and the core guide (700) is solidified within the through-holes and grooves formed in each member between the coil guide (300) and the core guide (700) and the gaps between each member, and portions in which the filling material is solidified by accumulating on the upper side of the lower cover (100) during the solidification process.

[0122] The coil (400) corresponds to the receiving coil described above and provides a path for the induced current to flow. In one embodiment, the coil (400) may be a Litz wire, which is a wire made by twisting three or more wires and spirally wound in a plane. The Litz wire has the advantage of maintaining a stable current flow and reducing the temperature rise of the coil. However, in a modified embodiment, the coil (400) may be a spirally wound single-strand enamel-coated wire or a polyurethane-coated polyurethane wire. Meanwhile, the coil (400) may be wound with a circular cross-section wire, but may also be implemented as a flat wire. Alternatively, the coil (400) may not be wound in a plane, but may be wound in a three-dimensional structure such that the height of the coil (400) is greater than the height of each turn of the coil (400). As shown in FIG. 8, lead wires (410, 412) can be attached to both ends of the coil (400), and the lead wire pair (410, 412) can extend to the outside of the receiving pad device (23).

[0123] The coil guide (300) can support the coil (400) from below. Support protrusions (310) for holding each turn of the coil (400) may be formed on the upper surface of the coil guide (300). The support protrusions (310) may be provided in correspondence to the number of turns of the coil (400). In addition, the support protrusions (310) may be provided at multiple locations on the coil guide (300). For example, in the embodiment illustrated in FIG. 9, support protrusions (310 to 324) are formed at eight locations on the upper surface of the coil guide (300), and 11 to 12 support protrusions (e.g., 310a to 310k) are formed at each of the eight locations so as to fix the coil (300) wound with 11 turns. Accordingly, the coil (400) can be fixed to the coil guide (300) by fitting each turn of the coil between adjacent support protrusions at each of the support protrusion installation positions (310 to 324). The support protrusions (310) enable the position and shape of the coil (400) to be maintained. In particular, when a Litz wire is used in the coil (400), the support protrusions (310) can help maintain the shape of the Litz wire consistently.

[0124] Meanwhile, as illustrated in FIG. 9, in an exemplary embodiment, a plurality of through holes (330) may be formed in the coil guide (300) so that a filler forming the filler member (200) may be filled therein. Meanwhile, in one embodiment, the coil guide (300) may be made of a PEEK material. Since this PEEK material has a thermal conductivity of about 0.2498 [W / m·℃], even when the temperature of the coil (400) increases, there may be no or minimal deformation due to heat.

[0125] The film (500) can prevent the coil (400) and the dielectric core (600) from coming into contact with each other. As illustrated in FIG. 10, in an exemplary embodiment, the film (500) may be formed with a plurality of through holes (510) so that a filler forming the filler member (200) can be filled therein. In an exemplary embodiment, the film (500) may be made of FR-4 material.

[0126] The dielectric core (600) helps form a magnetic path, which is a path through which the magnetic flux induced in the transmitting coil within the ground assembly (GA) of the EVSE flows, thereby enabling efficient power transmission. As illustrated in FIG. 11, in an exemplary embodiment, the dielectric core (600) may be manufactured in a rectangular plate shape. The type and permeability of the magnetic material constituting the dielectric core (600) may be determined in consideration of the size of the receiving pad device (23), the current and frequency applied to the transmitting pad (13), the type of the dielectric core of the transmitting pad (13), and the like.

[0127] The dielectric core guide (700) is disposed above the dielectric core (600) and supports the dielectric core (600) from above. FIG. 12 is a bottom view of the core guide (700) according to an exemplary embodiment of the present invention. As illustrated, a protrusion (710) extending along an edge of the bottom surface of the core guide (700) is formed. The dielectric core (600) can be seated on a plane inside the protrusion (710) of the core guide (700). That is, the protrusion (710) defines a seating surface (720) of the dielectric core (600). The vertical and horizontal sizes of the dielectric core seating surface (720) in the core guide (700) are respectively the same as the vertical and horizontal sizes of the dielectric core (600), so that the upper surface of the dielectric core (600) can be fitted into the dielectric core seating surface (720) provided on the bottom surface of the core guide (700). Accordingly, in the assembled state, the dielectric core (600) is fixed to the dielectric core guide (700) to prevent movement and maintain a state of being in close contact with the mounting surface of the dielectric core (600). Meanwhile, a plurality of through holes (730) are formed in the core guide (700) so that a filler forming the filling member (200) can be filled therein. In one embodiment, the dielectric core guide (700) may be made of a peak material.

[0128] The cooling unit housing (800) and the housing cover (900) are placed on the core guide (700). The cooling unit housing (800) and the housing cover (900) form a cooling unit when combined, and provide a cooling water circulation space so that heat generated in the receiving pad device (23) can be discharged to the outside through the cooling water and cooled. In addition, the combination of the cooling unit housing (800) and the housing cover (900) can accommodate a combination of the filling member (200), the coil guide (300), the coil (400), the film (500), the dielectric core (600), and the core guide (700) at its lower portion.

[0129] FIG. 13a is a perspective view of a cooling unit housing (800), FIG. 13b is a plan view of the cooling unit housing (800), and FIG. 13c is a drawing showing an example of a flow path of coolant in the cooling unit housing (800).

[0130] Referring to FIGS. 13a, 13b, and 13c, the cooling unit housing (800) has four upper corners, four lower corners, and four side surfaces (830) so as to have an overall shape similar to a rectangular parallelepiped. The cooling unit housing (800) may include an upper surface (840) extending inwardly in a horizontal direction from the four upper corners. The cooling unit housing (800) has a water channel (850) formed downwardly from the upper surface (840). The water channel (850) may be bent horizontally multiple times inside the cooling unit housing (800) and may be formed so as to increase the residence time of the cooling water. A plurality of vertical protrusions (854) are formed on the bottom surface (852) of the water channel (850) so as to protrude upward. The above-described plurality of vertical protrusions (854) not only guide the flow of cooling water flowing through the water channel (850) of the cooling unit, but also increase the heat transfer area, thereby enabling more efficient heat transfer from the bottom surface of the water channel, i.e., the bottom surface of the cooling unit housing (800), to the cooling water.

[0131] The depth of the water channel (850) is smaller than the height of the side surface (830) of the cooling unit housing (800), so that the combination of the filling member (200), the coil guide (300), the coil (400), the film (500), the dielectric core (600), and the core guide (700) can be accommodated on the lower side of the bottom surface (852) of the water channel (850). Both ends of the water channel (850) can be connected to an inlet (810) and an outlet (820), respectively. Accordingly, the cooling water introduced through the inlet (810) can flow along the water channel (850) and absorb heat through thermal contact with the bottom surface (852) and the vertical protrusion (854) of the cooling unit housing (800), and then be discharged through the outlet (820).

[0132] The housing cover (900) is coupled to the cooling unit housing (800) so that the cooling unit housing (800) is sealed upward, thereby preventing leakage of cooling water in the water channel (850) formed within the cooling unit housing (800). In addition, the housing cover (900) can perform an EMI shielding function by electromagnetically shielding the receiving pad device (23) and other components of the EV located above it at least partially. In one embodiment, the cooling unit housing (800) and the housing cover (900) may be made of aluminum.

[0133] Fig. 14a is a perspective view of the housing cover (900) viewed from the lower side, Fig. 14b is a plan view of the housing cover (900), and Fig. 14c is a bottom view of the housing cover (900).

[0134] Referring to FIGS. 14a, 14b, and 14c, the housing cover (900) is a roughly plate-shaped member having a plurality of screw holes formed on the inner side of the edge. The bottom surface of the housing cover (900) protrudes downward at a position corresponding to the water channel (850) of the cooling unit housing (800). Therefore, the edge of the bottom protrusion (910) of the housing cover (900) can be in close contact with the upper edge of the water channel (850) to sufficiently seal the water channel (850). Although not shown in the drawings, an additional sealing member may be used between the cooling unit housing (800) and the housing cover (900). Accordingly, when the cooling unit housing (800) and the housing cover (900) are coupled, the water channel (850) can be sealed by the cooling unit housing (800) and the housing cover (900) except for the inlet (810) and the outlet (820).

[0135] Referring to Fig. 15, a method for assembling a receiving pad device (23) will be described. Fig. 15 is a flowchart showing the assembly process of a receiving pad device (23) according to an exemplary embodiment of the present invention.

[0136] First, a coil (400), a film (500), a dielectric core (600), and a core guide (700) are sequentially placed on a coil guide (300) (step 1000). At this time, the coil (400) can be firmly inserted between the support protrusions (310) of the coil guide (300). In addition, the dielectric core (600) can be placed so as to be in close contact with the bottom surface of the core guide (700).

[0137] Next, the coil guide (300), coil (400), film (500), dielectric core (600), and core guide (700) can be fastened using a plurality of screws (step 1010). Screws made of peak material can be used as the plurality of screws.

[0138] Next, the coil guide (300), coil (400), film (500), dielectric core (600), and core guide (700), which are integrated by screw fastening, are placed in a pre-fabricated mold, a filler is injected, and the filler is solidified (step 1020). For example, a silicone resin may be used as the filler. Accordingly, a solidified filler (200) can be formed that fills the spaces between the respective members of the coil guide (300), coil (400), film (500), dielectric core (600), and core guide (700), and is partially collected at the bottom of the coil guide (300). Additionally, the filling member (200) may have a form that fills the through holes (330) of the coil guide (300), the through holes (510) of the film (500), the through holes (730) of the core guide (700), and the periphery of the dielectric core (600).

[0139] Finally, a coil subassembly in which a filling member (200), a coil guide (300), a coil (400), a film (500), a dielectric core (600), and a core guide (700) are integrated is placed on the lower cover (100), and additionally, a cooling unit housing (800) and a housing cover (900) are placed. Then, the lower cover (100), the cooling unit housing (800), and the housing cover (900) can be fastened using additional screws (999) (step 1030). The additional screws (999) may also be made of a peak material.

[0140] Accordingly, the assembly can be completed. Upon completion of the assembly, the filling member (200) can remain in close contact with the cooling unit housing (800), as well as the coil (400) and the dielectric core (600), which are members capable of generating a lot of heat. In addition, the cooling unit housing (800) and the housing cover (900) can form a sealed water channel (850).

[0141] The above receiving pad device (23) can operate as follows.

[0142] When wireless power transmission is initiated through communication between the SECC (14) and the EVCC (24), the transmitting pad (13) of the EVSE (10) generates a magnetic field so that high-energy level magnetic energy can be transmitted to the receiving pad device (23) of the EV device (20) through magnetic flux or magnetic resonance. The coil (400) of the receiving pad device (23) can receive high-energy level magnetic energy supplied in a magnetic resonance state, for example, by capturing the magnetic flux variation induced from the transmitting pad (13). The current flowing in the coil (400) due to the electromotive force induced in the coil (400) during the magnetic energy reception process is supplied to the EV-side power electronic circuit (22).

[0143] During this wireless power transmission process, considerable heat may be generated in the coil (400) and the dielectric core (600). The generated heat may be diffused through thermal contact between the respective members, particularly through the filling member (200) filling the gap within the receiving pad device (23), and transferred to the bottom surface of the cooling unit housing (800). In one embodiment, the filling member (200) formed of silicone resin has a thermal conductivity of 4 [W / m·℃] and may transfer the heat of the coil (400) and the dielectric core (600) to the cooling unit housing (800). In the cooling unit housing (800), the heat may be transferred to cooling water flowing in the water channel (850) through the bottom surface (852) and vertical protrusions (854) of the cooling unit housing (800), and may be discharged to the outside of the receiving pad device (23) through the cooling water.

[0144] The circulation of the cooling water within the water channel (850) of the cooling unit housing (800) can be achieved using a pump, and the cooling water circulated by the pump can be cooled by a separate heat exchange system. Fig. 16 is a block diagram of a heat exchange system according to one embodiment. In the embodiment of Fig. 16, the cooling water discharged from the discharge port (820) of the cooling unit housing (800) due to the suction force of the pump (1200) can be cooled by air blown by the fan (1220) in the radiator (1210) and then returned to the inlet port (810) of the cooling unit housing (800).

[0145] Meanwhile, in another embodiment, the heat exchange system may be shared with the heat exchange system for the engine coolant tank. Fig. 17 illustrates such an embodiment. This embodiment may be adopted, for example, in a hybrid electric vehicle, particularly a plug-in hybrid electric vehicle, that utilizes both engine and electric motor thrust. In the embodiment of Fig. 17, the pump (1200) may be fluidically connected to the engine coolant tank (1000) and the cooling unit housing (800), respectively, through, for example, two solenoid valves (1100, 1110). The solenoid valve (1100) may connect the engine coolant tank (1000) to the pump (1200) only when the engine is operating. At this time, the coolant contained in the engine coolant tank (1000) is supplied to the radiator (1210) due to the suction force of the pump (1200), and can be cooled by the air blown by the fan (1220) in the radiator (1210) and then returned to the coolant tank (1000). Meanwhile, the solenoid valve (1110) can connect the cooling unit housing (800) to the pump (1200) only when the engine is stopped and wireless power transfer is performed. At this time, the coolant discharged from the outlet (820) of the cooling unit housing (800) is supplied to the radiator (1210) due to the suction force of the pump (1200), and can be cooled by the air blown by the fan (1220) in the radiator (1210) and then returned to the inlet (810) of the cooling unit housing (800).

[0146] An experimental device was prepared according to the common specifications of the IEC 61980-3 standard and the SAE J2954 standard, and a cooling performance test was conducted. Figures 18a and 18b show the configuration of the device used for the performance test of the receiving pad device according to an exemplary embodiment. It was assumed that the ground assembly or transmitting pad (13) was installed in a form exposed to the ground, and the receiving pad (23) was installed so that the vehicle ground clearance was 100 to 150 mm, specifically, 110 mm, and an F-24-1 class inductive power transfer (IPT) type wireless power transmission device was used. A thermal analysis simulation was performed on the receiving pad device (23) with a water-cooling cooling device installed according to the exemplary embodiment and, as a control, a conventional receiving pad device without a water-cooling cooling device installed.

[0147] A simulation was conducted while varying the offset between the transmitting pad (13) and the receiving pad (23) to ±75 mm in the x-axis direction and ±100 mm in the y-axis direction. It was confirmed that as the horizontal offset from the vertical alignment position between the transmitting and receiving pads increased and the alignment became misaligned, the coupling coefficient between the transmitting and receiving pads decreased, resulting in a decrease in efficiency and heat generation. At this time, it was confirmed that the heat generated from the transmitting and receiving pads can be reduced through the water-cooling cooling device of the present invention. Specifically, in a conventional receiving pad device that does not include a water-cooling cooling device, the maximum temperature reached 113.9 ℃, whereas in a receiving pad device of an exemplary embodiment including a water-cooling cooling device, the maximum temperature was confirmed to be reduced by 69.2 ℃ to 44.7 ℃. Meanwhile, the water-cooling cooling device according to the exemplary embodiment can also be applied to the transmitting pad. In a conventional transmission pad device without a water-cooling device, the maximum temperature reached 69.5°C, whereas in the exemplary embodiment of the transmission pad device with a water-cooling device, the maximum temperature was confirmed to be 59.3°C, a decrease of 10.2°C.

[0148] Although the present invention has been described above with reference to preferred embodiments thereof, it will be understood by those skilled in the art that various modifications and changes may be made to the present invention without departing from the spirit and scope of the present invention as set forth in the claims below.

Claims

1. As a wireless power transmission pad device, A dielectric core that provides a magnetic flux conductor; A coil providing a path through which a current associated with the magnetic flux flows; A cooling unit providing a water channel for cooling water to at least partially receive and dissipate heat generated from one or more of the dielectric cores or the coils to the outside; and A filling member that is at least partially filled inside the wireless power transmission pad device and is formed to be in close contact with at least one of the dielectric core or the coil so as to assist the heat conduction process from the dielectric core or the coil to the cooling unit; A wireless power transmission pad device including:

2. In claim 1, The above magnetic flux is generated from the external transmitting pad, The above coil is a receiving coil that provides a path through which an induced current induced from the magnetic flux flows. Wireless power transmission pad device.

3. In claim 1, A core guide for preventing the flow of the above dielectric core; and A coil guide for fixing the above coil; A wireless power transmission pad device further comprising:

4. In claim 3, In each of the core guide and the coil guide, a plurality of vertical through holes are formed so that the filling material can be filled. Wireless power transmission pad device.

5. In claim 4, A film disposed between the dielectric core and the coil to prevent direct contact between the dielectric core and the coil; A wireless power transmission pad device further comprising:

6. In claim 5, In the above film, a plurality of through holes are formed at positions corresponding to the plurality of vertical through holes formed in the core guide and the coil guide. Wireless power transmission pad device.

7. In claim 1, the cooling unit A cooling unit housing arranged to be in contact with the above-mentioned filling member, including the water channel formed by being recessed from the upper surface, and having an inlet and an outlet for the water channel provided; and A housing cover positioned on the upper portion of the cooling unit housing and sealing the water channel from above; A wireless power transmission pad device including:

8. In claim 7, the water channel of the cooling unit housing is opened toward the direction in which the housing cover is arranged, On the surface of the housing cover facing the water channel, a protrusion corresponding to the water channel is formed so as to cover and seal the water channel. Wireless power transmission pad device.

9. In claim 7, a plurality of vertical protrusions are formed on the bottom surface of the water channel so as to protrude upward so as to guide the flow direction of the cooling water and increase the heat transfer area of ​​the cooling water channel. Wireless power transmission pad device.

10. In claim 1, the cooling unit includes a plurality of sides, and the bottom surface of the water channel is higher than the lower ends of the plurality of sides, so that a receiving space is formed on the inner side toward the center of the plurality of sides. The dielectric core, the coil, and the filling member are accommodated in the above-mentioned accommodation space. Wireless power transmission pad device.

11. In claim 10, Further comprising a base cover supporting the wireless power transmission pad device on the opposite side of the cooling unit; In a state where the dielectric core, the coil, and the filling member are arranged between the base cover and the cooling unit, the base cover and the cooling unit are fastened with screws. Wireless power transmission pad device.

12. A method for manufacturing a wireless power transmission pad, A step of providing members including a dielectric core providing a path for magnetic flux and a coil providing a path for a current associated with the magnetic flux to flow; A step of creating a coil subassembly by injecting a predetermined filler into the space between the above-mentioned members and solidifying the filler to form a filler member; and A step of securing a cooling unit to the coil subassembly, the cooling unit providing a water channel for cooling water to at least partially receive and dissipate heat generated from one or more of the dielectric cores or the coils to the outside; A method for manufacturing a wireless power transmission pad, comprising:

13. In claim 12, The above magnetic flux is generated from a transmitting pad located outside the wireless power transmission pad, The above coil is a receiving coil that provides a path through which an induced current induced from the magnetic flux flows. Method for manufacturing a wireless power transmission pad.

14. In claim 12, the step of forming the filling member comprises: A step of fastening the above-mentioned members including the above-mentioned dielectric core and the above-mentioned coil; and A step of forming a filling member by injecting and solidifying the above filler; A method for manufacturing a wireless power transmission pad, comprising:

15. In claim 12, the step of fixing the cooling unit to the coil subassembly A step of arranging the coil subassembly and the cooling unit on a base cover, and fastening the base cover, the coil subassembly, and the cooling unit; A method for manufacturing a wireless power transmission pad, comprising:

16. A method for manufacturing a wireless power transmission pad according to claim 15, wherein the base cover, the coil subassembly, and the cooling unit are fastened using screws made of a peak material.

17. In claim 12, the above-mentioned members A core guide for preventing the flow of the above dielectric core; A coil guide for fixing the above coil; and A film disposed between the dielectric core and the coil to prevent direct contact between the dielectric core and the coil; Including more, A plurality of through holes are formed in each of the core guide, the coil guide, and the film so that the filling material can be filled. Method for manufacturing a wireless power transmission pad.

18. In claim 12, the step of fixing the cooling unit to the coil subassembly A step of arranging a cooling unit housing including the water channel formed by recessing from the upper surface and having an inlet and an outlet for the water channel so as to be in contact with the filling member; A step of placing a housing cover that seals the water channel from above on the upper part of the cooling unit housing; and A step of fastening the coil subassembly, the cooling unit housing, and the housing cover; A method for manufacturing a wireless power transmission pad, comprising:

19. In claim 18, the water channel of the cooling unit housing is opened toward the direction in which the housing cover is arranged, and a protrusion corresponding to the water channel is formed on the surface of the housing cover facing the water channel so as to cover and seal the water channel. On the bottom surface of the above water channel, a plurality of vertical protrusions are formed to protrude upward so as to guide the flow direction of the cooling water and increase the heat transfer area of ​​the cooling water channel. Method for manufacturing a wireless power transmission pad.

20. In claim 12, the cooling unit includes a plurality of sides, and the bottom surface of the water channel is higher than the lower ends of the plurality of sides, so that a receiving space is formed on the inner side toward the center of the plurality of sides. The step of securing the above cooling unit to the above coil subassembly is A step of placing the coil subassembly and the cooling unit on a base plate while the coil subassembly is inserted into the receiving space; and A step of fastening the base plate and the cooling unit; A method for manufacturing a wireless power transmission pad, comprising:

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