Method and device for producing an inductive charging unit, carrier and inductive charging unit

Abstract

The invention relates to a method for producing an inductive charging unit (2), in which method at least one electrical conductor (3) is inserted into a mould (5) and an insulating material is then supplied to the mould (5). In the method, the electrical conductor (3) is, for example, wound spirally during insertion into the mould (5). The invention additionally relates to a device (1), a carrier (6) and an inductive charging unit (2).

Description

[0001] 1 SMS-11226a-24

[0002] August 27, 2025

[0003] Method and apparatus for manufacturing an inductive charging unit, carrier and inductive charging unit

[0004] The present invention relates to a method for manufacturing an inductive charging unit, in which at least one electrical conductor is placed in a mold and an insulating material is subsequently added to the mold. The present invention further relates to a device for manufacturing an inductive charging unit, a carrier for an inductive charging unit and / or a flat coil, and an inductive charging unit.

[0005] German patent application DE 10 2019 209 141 A1 discloses a method for manufacturing an inductive charging device. In this method, a ferrite core and a coil wound from a stranded wire are placed in a mold and at least partially encased in plastic. A disadvantage of this method is that a weld seam can form when a carrier for the wire is used. Additionally or alternatively, air inclusions can occur during the encasement process, particularly if the mold is filled too quickly and / or without a vacuum. The weld seam and / or the air inclusions represent an undesirable weak point in the plastic casing. Additionally or alternatively, the wire is already wound when placed in the mold, which makes the method inflexible, as the coil must be wound beforehand and / or within the carrier. Additionally or alternatively, the winding of the wire is predetermined, for example, by the carrier.

[0006] The object of the present invention is to eliminate the disadvantages known from the prior art.

[0007] The problem is solved by a method and a device for manufacturing an inductive charging unit, by a carrier and an inductive charging unit with the features of the independent claims. 2 SMS-11226a-24

[0008] August 27, 2025

[0009] Advantageous or preferred embodiments or further developments of the invention are characterized by the features of the dependent claims.

[0010] A method for manufacturing an inductive charging unit and / or a charging unit manufacturing process is proposed. The inductive charging unit is preferably used for the inductive charging of an electrical energy storage device, for example, in a motor vehicle. By using inductive charging units, electrical energy storage devices can be charged without contact and therefore without wear.

[0011] In this process, at least one electrical conductor is preferably placed in a mold. The at least one electrical conductor is preferably designed as a stranded wire, wire, foil, or tube and / or comprises a conductive material, for example, copper, silver, and / or aluminum. Additionally or alternatively, the electrical conductor is flexible. Additionally or alternatively, the electrical conductor is bendable and, particularly after a cooling period, dimensionally stable. The bendability of the electrical conductor enables flexible manufacturing, while the dimensional stability after the cooling period ensures the mechanical integrity of the coil. Preferably, an insulating material is subsequently added to the mold. Adding an insulating material ensures electrical insulation and protects the conductor from external influences.

[0012] Preferably, the mold is designed as a casting mold, in particular an injection mold, and / or the insulating material is injected and / or introduced into the mold. Additionally or alternatively, the insulating material and / or a carrier material is supplied to the mold in liquid form. Additionally or alternatively, the insulating material and / or a carrier material is introduced under low pressure and / or slightly elevated pressure. The mold preferably has atmospheric pressure inside. This makes it sufficient to introduce the insulating material and / or the carrier material under slightly elevated pressure. This simplifies the introduction of the insulating material and / or the carrier material into the interior of the mold and / or 3 SMS-11226a-24

[0013] August 27, 2025, reduces the need for special equipment. The inductive charging unit thus preferably comprises at least the electrical conductor and a casing formed from the insulating material. Additionally or alternatively, the inductive charging unit can comprise a support and / or at least one functional element and / or at least one reinforcing element and / or at least one stiffening element.

[0014] Preferably, the electrical conductor is wound spirally during insertion into the mold. When used in an inductive charging unit, the at least one electrical conductor is preferably wound within a single winding plane, thus comprising several turns. Preferably, the electrical conductor is wound as a flat coil. Because the electrical conductor is wound during insertion into the mold, at least one process step can be omitted. A support for the electrical conductor is not strictly necessary, but can be used. After winding, the electrical conductor is preferably arranged in the mold in a dimensionally stable manner. Since the electrical conductor is wound during insertion into the mold, a winding die or a winding support is not strictly necessary. Additionally or alternatively, the electrical conductor can be encased in the insulating material during the winding process.For example, it is conceivable that production could take place as flow production or assembly line production. In such a production process, the mold can first be provided, the electrical conductor wound into the mold, and then sheathed.

[0015] Preferably, in a first feeding step, a carrier material is fed into the mold to produce a support for the electrical conductor. In a second feeding step, the insulating material is fed into the mold to at least partially encase the electrical conductor. This can additionally or alternatively lead to increased efficiency and / or a reduction in process steps. Additionally or alternatively, this can facilitate flow production. 4 SMS-11226a-24

[0016] 27.08.2025 or assembly line production will be extended by the step of carrier production.

[0017] As described above, the insulating material and / or the carrier material is preferably supplied in liquid form. Supplying the liquid carrier material ensures a homogeneous distribution and uniform encapsulation of the electrical conductor. Additionally or alternatively, it is conceivable that the insulating material and / or the carrier material is designed as a semi-finished product, for example, as a sheet, particularly a plastic sheet. The use of semi-finished products allows for quick and easy handling in the manufacturing process. In particular, it is conceivable that the carrier is designed as a deep-drawn carrier. Here, too, the carrier can be designed in two parts and / or include cavities and / or cutouts and / or be porous and / or comprise a grid-like structure.

[0018] Additionally or alternatively, it is conceivable that the carrier is fed into the mold in a single insertion step. Following this insertion step, the electrical conductor is preferably wound into the carrier. After winding, a second feeding step preferably takes place, in which the insulating material is fed into the mold and the electrical conductor and / or the carrier is encased. Encasement of the electrical conductor and / or the carrier with insulating material ensures the electrical insulation and mechanical stability of the inductive charging unit.

[0019] Preferably, or alternatively, the support and the electrical conductor held spirally by the support are completely and / or seamlessly encased by the insulating material. This ensures that the casing encases the flat coil as completely as possible or that the inductive charging unit is completely encapsulated. Additionally or alternatively, a casing made of the insulating material is thus as resistant as possible. 5 SMS-11226a-24

[0020] August 27, 2025

[0021] A durable casing protects the components of the inductive charging unit from mechanical damage and environmental influences.

[0022] Preferably, or alternatively, the insulating material is supplied to at least one cavity formed within the support and / or between the support and the electrical conductor held spirally by the support. A cavity is understood to be a space within the support and / or between the support and the electrical conductor to be accommodated, which is suitable for supplying the insulating material. Thus, the at least one cavity is preferably designed as a cavity that is open, particularly at least on one side. This can, for example, increase the mechanical stability and electrical insulation of the inductive charging unit. The support can thus be at least partially penetrated by the insulating material of the inductive charging unit.Additionally or alternatively, the casing of the inductive charging unit, formed from the insulating material, can abut the electrical conductor on both sides, at least partially, along a radial direction and / or the vertical direction of the support and / or the flat coil, via at least one cavity. This improves the encapsulation and / or prevents defects or unintended weak points.

[0023] Preferably, an additional or alternative venting step is performed before, during, and / or after the feeding of the insulation material. This prevents and / or reduces air inclusions in the insulation material. Preventing air inclusions results in a more uniform and reliable insulation layer. This can contribute to improved insulation, particularly in casting processes where the mold is not vented by a vacuum. 6 SMS-11226a-24

[0024] August 27, 2025

[0025] The process features and / or process steps described above and / or below can be used and / or carried out independently of each other and / or in any combination.

[0026] It is advantageous if the electrical conductor is wound into the shape using a free-bending step, particularly freely and / or without a support and / or independently of a support. The free-bending step can also be called a free-winding step and / or a laying step. In this process, the electrical conductor can be plastically and / or elastically deformed. Additionally or alternatively, the electrical conductor can be wound and / or laid as a flexible conductor.

[0027] The free-bending step allows for flexible design of the winding shape and reduces the need for additional tools, components, and / or semi-finished products. A free-bending step is thus understood as a winding technique for the electrical conductor in which the winding shape is determined by the winding process and not directly by the substrate (and its receiving grooves). Here, the electrical conductor is preferably laid using a routing unit. The routing unit ensures precise and controlled winding of the electrical conductor. Preferably, the routing unit is designed as a CNC routing unit and / or includes a CNC control. Preferably, the electrical conductor can be laid in the free-bending step, and in particular exclusively, based on input parameters. The input parameters describe the winding shape. The control preferably includes an input device with which the input parameters can be entered.Preferably, the laying unit is controlled such that the winding shape of the electrical conductor is formed. Control of the laying unit enables precise adaptation of the winding shape of the flat coil and / or the electrical conductor to the specific requirements of the inductive charging unit. It should be noted that the free-bending step does not have to be performed in the form, but can be. 7 SMS-11226a-24.

[0028] August 27, 2025

[0029] It is also advantageous if at least two conductor turns are formed during the winding of the electrical conductor, preferably with all, and preferably all, of the conductor turns being arranged within a single winding plane. The winding unit preferably positions the electrical conductor within this winding plane. If this is done using the free-bending step, the complexity can be reduced by positioning the conductor within the winding plane. Additionally or alternatively, it is conceivable that at least two of the conductor turns are arranged in different winding planes. In this way, a flat coil with two conductor planes can be produced. Such flat coils can be called, for example, double flat coils and / or multiple flat coils.

[0030] It is also advantageous if the electrical conductor, especially during the free-bending step, can be wound with a radial spacing between the multiple conductor turns. A radial spacing between the conductor turns prevents short circuits and ensures electrical insulation from each other.

[0031] It is also advantageous if, during winding, particularly with the aid of a winding unit and / or a winding head, the distance between the conductor turns can be set, adjusted, and / or changed so that a variable conductor winding spacing can be produced and / or implemented. A variable spacing allows the winding to be adapted to specific requirements and improves flexibility in the production process. The spacing can, for example, be defined and / or predefined by the input parameters.

[0032] It is also advantageous if the electrical conductor is completely and / or seamlessly encased by the insulating material and / or if the insulating material forms a sheath around the electrical conductor. Complete and seamless encasement improves electrical insulation and protects the conductor from mechanical damage. 8 SMS-11226a-24

[0033] August 27, 2025

[0034] It is also advantageous if, during the winding of the electrical conductor, the mold, in particular the base of the mold, and / or the laying unit, in particular the laying head, is moved. Moving the mold or the laying unit during winding enables precise positioning and uniform winding of the electrical conductor. Additionally or alternatively, the support is moved during the winding of the electrical conductor, in particular together with the mold and / or in the state inserted into the mold.

[0035] Furthermore, it is advantageous if the electrical conductor is at least partially covered with a sheath, in particular extruded insulation, tubing, and / or conductor sheath, before and / or after winding. An additional sheath provides an extra layer of protection and / or improves the mechanical stability and electrical insulation of the conductor.

[0036] There are advantages to heating the sheath, especially if it is a plastic or thermoplastic sheath, before and / or during winding the electrical conductor, so that the conductor and sheath are flexible. Heating the sheath increases its flexibility and facilitates handling during winding.

[0037] It is also advantageous if the sheath, particularly a plastic sheath and / or thermoplastic sheath and / or thermoset sheath, is fixed after winding and / or before the second feeding step by solidification, especially by cooling and / or curing (for example, using a baking varnish). Preferably, after a cooling period, the sheath is fixed within the mold. Cooling the sheath after winding increases the dimensional stability and mechanical strength of the sheathing. Thus, after the sheath has cooled, the electrical conductor can be sheathed with the insulating material. The cooled sheath reduces the risk of deformation of the electrical conductor during sheathing. 9 SMS-11226a-24

[0038] August 27, 2025

[0039] The resistance of the conductor, especially when subjected to external influences such as the application of insulating material, can be reduced. Particularly when the electrical conductor is sheathed, it is conceivable, either additionally or alternatively, that the sheathed conductor is only partially encased by the insulating material. In this way, the sheath can already provide sufficient and / or at least partial protection for the electrical conductor from environmental influences and / or ensure electrical insulation. By additionally partially encasing the sheathed electrical conductor with the insulating material, the resistance of the inductive charging unit can be further increased.

[0040] It is also advantageous if the electrical conductor is fixed during and / or after winding, particularly by means of a clamping device. Preferably, at least one end of the electrical conductor is fixed. Fixing the conductor and / or the at least one end prevents the electrical conductor from slipping and ensures precise positioning. This clamping can be released during and / or after the second feeding step.

[0041] It is also advantageous if the carrier is inserted into the mold before winding and / or the electrical conductor is held against the carrier, in particular at least one retaining section and / or in at least one receiving groove of the carrier. Inserting the carrier before winding provides a stable base and facilitates the precise positioning of the electrical conductor. The retaining sections and receiving grooves ensure secure fixation of the conductor during the winding process.

[0042] It is also advantageous if a connecting surface of the carrier is prepared, in particular physically and / or chemically, preferably before the second feeding step. Physical preparation can be carried out, for example, using a plasma. Chemical preparation can be carried out using 10 SMS-11226a-24

[0043] For example, this can be done on August 27, 2025, using an adhesion promoter. The physical or chemical treatment of the bonding surface improves the adhesion of the insulating material and increases the mechanical stability and / or encapsulation of the inductive charging unit. This contributes to improved electrical insulation and the longevity of the coil.

[0044] It is also advantageous if the curing time of the substrate material between the first and second feeding steps is shorter, so that the substrate is not yet, or not yet fully, cured when the insulating material is added. Adding the insulating material while the substrate is still curing allows for a better bond. This results in a more homogeneous structure and improves the mechanical strength of the finished inductive charging unit. Additionally or alternatively, this can reduce the risk of weld lines and / or unwanted weak points.

[0045] It is also advantageous if an electrically and / or thermally insulating plastic, in particular a thermoplastic, and / or resin, in particular a synthetic resin, is used and / or applied to the mold as insulation material and / or as a carrier material. The use of electrically and thermally insulating materials protects the electrical conductor and / or the at least one functional element from external influences, for example, during installation. To protect the electrical conductor and / or the at least one functional element during the intended use of the inductive charging unit, the insulation material and / or the carrier material can be provided with additives. This allows the ratio of heat dissipation (for example, during operation of the inductive charging unit) to thermal insulation (for example, during installation of the inductive charging unit) to be adjusted.Thermoplastics and synthetic resins offer good formability and resistance to high temperatures and mechanical stresses. Additionally or alternatively, the carrier can thus be a 11 SMS-11226a-24.

[0046] 27.08.2025 include sufficient rigidity for assembly and / or sufficient flexibility for intended use in the inductive charging unit.

[0047] It is also advantageous if the insulation material and / or the carrier material is heated and / or fed into the mold in a viscous state, the heated insulation material and / or carrier material preferably being viscous. Heating the material facilitates filling and ensures uniform distribution within the mold. As already described, the insulation material and / or the carrier material can be fed in liquid form. The viscous consistency of the material improves its flow properties and prevents air entrapment, resulting in better insulation.

[0048] It is also advantageous if the carrier is held within the mold, particularly mechanically and / or with the aid of a vacuum and / or a clamping device. Holding the carrier with the aid of a vacuum ensures precise positioning and prevents slippage during the manufacturing process. This contributes to a uniform distribution of the insulating material and consistent quality of the inductive charging unit.

[0049] It is also advantageous if the mold is at least partially changed between the first and second feeding steps, and / or if it is converted from a carrier mold for the carrier material to a shell mold for the insulation material. This allows the contours of the carrier and the shell to differ. This creates a more flexible process and / or increases the possibilities for variation.

[0050] It also offers advantages if the mold base is used as a common mold base for both the carrier mold and the shell mold, and / or at least one mold lid is used during the changeover. 12 SMS-11226a-24

[0051] The components between the support mold and the shell mold are exchanged on August 27, 2025. Preferably, the support mold comprises the mold base and a support mold lid, and / or the shell mold comprises the mold base and the mold lid. The use of a common mold base simplifies the manufacturing process and reduces the number of components required. For example, the support can be created using the common mold base, and / or the electrical conductor can be inserted into the common mold base, particularly wound. This leads to cost savings and accelerates production.

[0052] Furthermore, it is advantageous if the electrical conductor is inserted, and in particular wound, into the support mold, the casing mold, and / or the mold base. This allows for precise positioning and winding of the conductor. This ensures uniform distribution and optimal electrical performance of the inductive charging unit. Winding the electrical conductor into the casing mold and / or the (common) mold base can accelerate production, as the sheathing of the electrical conductor can then be carried out immediately after winding, particularly without prior relocation and / or repositioning of the conductor.

[0053] It is also advantageous if, before the insulating material is added and / or after the winding of the at least one electrical conductor, at least one functional element, in particular at least one capacitor, an interface, a monitoring device and / or a computing device, is inserted into the mold, in particular into the shell and / or the mold base. The interface can be, for example, a radio interface or a cable interface. Additionally or alternatively, the interface can be a data interface and / or a power transmission interface. For example, data can be transmitted using the interface. Additionally or alternatively, the capacitor and / or the electrical conductor can be connected to each other and / or to the 13 SMS-11226a-24 using the interface.

[0054] August 27, 2025

[0055] Energy transmission is connected to a power supply. The monitoring device can, for example, include at least one sensor and / or a detection element. This integration enables the monitoring and control of the inductive charging unit and improves the safety and efficiency of the charging process. Additionally or alternatively, the functional element can also be protected by the casing and / or potential unintended weak points in the casing can be avoided.

[0056] Advantages arise if at least one reinforcing element is inserted into the mold, particularly the shell and / or the mold base, and / or positioned at the at least one conductor end before the insulating material is added and / or after the at least one electrical conductor is wound. The reinforcing element can, for example, be designed as a sandwich insulating material. With its help, two conductor layers and / or two conductor loops can be electrically separated and / or insulated from each other before overmolding. Such conductor layers can be created, for example, when the electrical conductor is routed radially outwards over and / or under the mold. Additionally or alternatively, the insertion of reinforcing elements increases the mechanical stability and durability of the inductive charging unit. This contributes to improving the reliability and service life of the entire system.

[0057] It is also advantageous to heat, temper, and / or maintain a curing temperature in the electrical conductors and / or the mold. Heating and tempering the electrical conductors and / or the mold ensures a uniform distribution of the insulation material and optimal curing. Tempering can thus accelerate the curing process of the insulation material. 14 SMS-11226a-24

[0058] August 27, 2025

[0059] It is also advantageous to move the mold and / or the material feed for the insulating material and / or the carrier material before or during the venting step, particularly by tilting and / or swiveling it. Moving the mold before or during the venting step can reduce air inclusions in the insulating material. For example, the mold and / or the material feed can be swiveled before the venting step and held in a tilted position during the venting step. This tilting position allows the air to escape from the mold on one side. This results in more homogeneous and reliable insulation or encapsulation of the inductive charging unit.

[0060] Furthermore, it offers advantages to perform a functional test of at least one electrical conductor and / or at least one functional element after the insulation material has been added and / or before the tempering step and / or during the tempering step and / or after the tempering step and / or before removing the inductive charging unit from the mold. A functional test before removing the inductive charging unit from the mold ensures that all components are functioning correctly. This increases the quality and reliability of the manufactured inductive charging unit.

[0061] It is also advantageous if the at least one electrical conductor and / or the conductor windings formed from the at least one electrical conductor are held in place after being inserted into the mold, particularly by means of at least one holding element, for example, the mold itself, wherein preferably the at least one holding element is removed from an interior of the mold after the insulating material has been added and / or during the venting step and / or before the tempering step and / or during the tempering step. Holding the electrical conductor with a holding element ensures precise positioning during the manufacturing process. Removing the holding element after adding the 15 SMS-11226a-24

[0062] August 27, 2025

[0063] The insulating material ensures a uniform encapsulation. If the retaining element is removed from an interior part of the mold during the venting step and / or before and / or during the tempering step, the insulating material already present in the mold fills the resulting cavities. This can be improved, for example, by moving the mold and / or the material feed during the venting step.

[0064] Furthermore, a device for manufacturing an inductive charging unit is proposed. The device preferably comprises at least one mold with which at least one carrier of the inductive charging unit can be produced from a carrier material and / or at least one casing of the inductive charging unit can be produced from an insulating material. The device enables the efficient and precise manufacturing of inductive charging units by using the mold to produce the carrier and / or the casing.

[0065] Preferably, the device comprises at least one laying unit with which an electrical conductor of the inductive charging unit can be inserted into the at least one mold. Preferably, the electrical conductor is wound as a flat coil. The laying unit ensures precise and uniform placement of the electrical conductor in the mold. In the prior art, it is known to pre-wind the electrical conductor, for example, with the aid of a carrier and / or with the aid of a baking varnish, and then insert it into the mold. With the laying unit, the electrical conductor can already be wound into the mold, thereby eliminating at least one manufacturing step. This can accelerate production and / or reduce material costs.

[0066] Preferably, the mold additionally or alternatively comprises a mold base into which the electrical conductor can be inserted and the insulating material can be supplied. A mold base provides a stable foundation for inserting the electrical conductor and supplying the insulating material. 16 SMS-11226a-24

[0067] August 27, 2025

[0068] Preferably, the device additionally or alternatively comprises at least one venting device with which a venting step of the mold can be carried out. The venting device prevents air inclusions in the insulating material and contributes to a homogeneous and / or defect-free encapsulation or sheathing of the electrical conductor. Preferably, the venting device includes a tilting mechanism. For example, the mold can be vented by moving it, in particular by tilting it. Preferably, the air can escape through vent openings in the mold. This improves the material distribution within the mold.

[0069] Preferably, the device additionally or alternatively comprises at least one control unit. The control unit is preferably configured to control the device according to the method described above, wherein the aforementioned method features can be implemented individually or in any combination. The control unit enables the automatic and precise execution of the manufacturing process, particularly as described above, which increases the efficiency and quality of production.

[0070] The features of the device described above and / or below can be used independently of each other and / or in any combination.

[0071] It is also advantageous if the mold includes at least a mold lid and / or a mold base and / or another mold section and / or a locking mechanism and / or a seal and / or a vent and / or a coating and / or a material feed.

[0072] The locking mechanism allows the mold lid, mold base, and / or the subsequent mold section to be locked and / or secured. This allows the insulation material 17 SMS-11226a-24 to be inserted during the first and / or second feeding step.

[0073] 27.08.2025 and / or the carrier material is injected into the mold under pressure. The seal can be used to seal the mold lid, the mold base, and / or the remaining mold section. This prevents the injected material from escaping. The vent allows air contained in the mold to escape. The coating facilitates demolding of the finished inductive charging unit. The coating can, for example, be designed as a non-stick surface, particularly a durable non-stick surface. The material feed can be used to supply the carrier material and / or the insulating material. The material feed is preferably openable and closable. The aforementioned components contribute to flexible and reliable use of the mold, which improves manufacturing efficiency and product quality.

[0074] It is also advantageous if the device includes at least one fixing device and / or one temperature control device and / or one testing device and / or one processing device and / or one positioning device and / or one control system. These additional devices enable comprehensive control and / or optimization of the manufacturing process, leading to higher product quality and efficiency.

[0075] The fixing device allows, for example, the carrier to be fixed within the mold, particularly using a vacuum and / or mechanically. This can be achieved, for example, by surface suction. The temperature control device allows the temperature control step to be carried out. For example, the temperature control device comprises at least one heating element. The testing device allows the functional test to be performed and / or supported. The preparation device allows the bonding surface of the carrier to be prepared and / or treated so that the bond to the supplied insulating material is improved. The preparation device preferably comprises a plasma application medium and / or a nozzle for the adhesion promoter. The positioning device allows the at least one functional element and / or the 18 SMS-11226a-24

[0076] 27.08.2025 at least one stiffening element will be inserted into the mold and / or positioned within the mold.

[0077] It is also advantageous if the device, in particular the laying unit, includes at least one laying head and / or a form carrier and / or a conductor feed and / or a movement device and / or a clamping device and / or a disconnecting device and / or a conductor heater. These components improve the precision and efficiency of laying the electrical conductor and contribute to higher product quality and consistency.

[0078] The laying head allows the electrical conductor to be placed in the mold and / or wound. Preferably, the laying head comprises at least one roller and / or a funnel and / or a pressure roller and / or a conductor heater. The conductor heater allows the electrical conductor to be heated so that the conductor and its sheath are flexible. The mold carrier supports the mold and / or the mold base. Preferably, the mold carrier can be arranged on a conveyor belt and / or is designed as a conveyor belt. The conductor feed allows the electrical conductor to be fed to the laying head. Preferably, the conductor feed is controlled, in particular by the control system, so that the feed is demand-based. The movement device allows the mold, the mold carrier, and / or the at least one laying head to be moved relative to each other, in particular along two axial directions.The electrical conductor can thus be freely bent and / or wound, particularly within the winding plane. This can also be controlled by the control system, especially a CNC control system. The clamping device allows the electrical conductor to be clamped and / or fixed, particularly at the conductor ends. The disconnecting device allows the electrical conductor to be disconnected. The disconnecting device can be designed, for example, as a mechanical disconnecting device and / or a heat-disconnecting device. 19 SMS-11226a-24.

[0079] August 27, 2025

[0080] Furthermore, a support for an inductive charging unit and / or a flat coil, in particular a coil support and / or a flat coil support, is proposed. The support allows for the placement and / or fixing of an electrical conductor of the flat coil and / or the inductive charging unit. Preferably, the support comprises a receiving groove, open along a vertical direction of the support and spirally shaped, for receiving the spiral electrical conductor. The spiral receiving groove facilitates the insertion and fixing of the electrical conductor and ensures a uniform distribution of the windings.

[0081] Preferably, the receiving groove is interrupted by at least one recess for insulating material. The recess allows the insertion of insulating material, thereby improving the electrical insulation of the conductor. Preferably, at least one cavity for insulating material of the inductive charging unit can be formed between the at least one recess of the support and the receiving electrical conductor, preferably along the vertical direction and / or along a radial direction on both sides of the electrical conductor. The cavities, or the at least one cavity, enable efficient distribution of the insulating material and improve the mechanical stability of the inductive charging unit. A received electrical conductor, in particular shaped and / or designed as a flat coil, can, for example, be spaced apart from the support along the vertical direction and / or radial direction.

[0082] Additionally or alternatively, the support is porous and / or designed as a foam with at least one cavity, in particular a porous and / or cellular one. Thus, the porous and / or foam-like support can already provide the cavity. An additional recess is not strictly necessary, but can lead to even better insulation. A porous or foam-like support allows for better integration and / or penetration of the insulation material. For example, 20 SMS-11226a-24

[0083] By August 27, 2025, the support can be made of a plastic foam, foam, and / or polymer foam. The porous support can additionally or alternatively be manufactured as a 3D-printed component and / or using additive manufacturing. This allows the support to be at least partially permeable to the insulating material of the inductive charging unit. This ensures a uniform distribution of the insulating material and increases the overall strength of the structure. Additionally or alternatively, a casing for the inductive charging unit, formed from the insulating material, can abut the electrical conductor on both sides, at least partially, along a radial direction and / or the vertical direction, through the at least one cavity. This arrangement improves the encapsulation of the conductor and prevents defects.

[0084] It is also advantageous if the support is designed as a grid. The grid-like design reduces the weight of the support while maintaining sufficient strength. Additionally or alternatively, it is beneficial if the support incorporates a honeycomb structure. The honeycomb structure combines high mechanical strength with minimal material usage. This allows a support with suitable mechanical properties to be produced using as little plastic material as possible. Additionally or alternatively, the optionally added insulation material can be injection-molded through the honeycomb structure.

[0085] Additionally or alternatively, it is advantageous if the support is designed in multiple parts, particularly two parts. The multi-part support can comprise a first support section and / or a second support section. This simplifies assembly and / or enables automated assembly in the manufacturing process. Additionally or alternatively, the support includes at least one hinge section. The integrated hinge section increases the flexibility of the support without adversely affecting its structural stability. The hinge section can selectively position the support in the 21 SMS-11226a-24

[0086] August 27, 2025

[0087] Design directions that are movable and / or pivotable in which lower structural stability is permissible.

[0088] It is also advantageous if the first and second support sections can be locked together. A locking mechanism creates a positive connection between the two support sections, particularly without additional connecting elements. This improves assembly efficiency and minimizes potential sources of error. Additionally or alternatively, this can also secure at least one electrical conductor and / or at least one functional element.

[0089] Furthermore, it is advantageous if at least one receiving section is formed between the first support section and the second support section for receiving the at least one electrical conductor and / or the at least one functional element of the inductive charging unit and / or the flat coil. The targeted design of receiving sections ensures precise positioning of the electrical conductor, the supply line, the overall supply line, and / or the functional elements.

[0090] It is also advantageous if the support, in particular the first support section and / or the second support section, preferably at the receiving section, comprises at least one retaining section for the at least one electrical conductor and / or the at least one functional element. A retaining section reliably secures the components against displacement due to vibration, during manufacturing, and / or temperature changes. The at least one retaining section can hold and / or stabilize the at least one electrical conductor and / or the at least one functional element along the radial direction and / or along the vertical direction.

[0091] Additionally or alternatively, the spiral receiving groove for multiple conductor turns of the electrical conductor includes several along a 22 SMS-11226a-24

[0092] August 27, 2025

[0093] The radial direction of the carrier and / or the flat coil is defined by spaced-apart groove sections, where several, in particular at least two, of the gaps are of different sizes. The different spacings of the groove sections allow for flexible adaptation to various winding geometries and / or requirements. Furthermore, the different spacings support the laying unit during the free-bending step.

[0094] The carrier features described above and / or below can be used independently of each other and / or in any combination.

[0095] It is advantageous if the support is designed as a single piece. A one-piece design increases stability and simplifies manufacturing.

[0096] It is also advantageous if the carrier includes at least one feature from the previous description, whereby the mentioned features can be present individually or in any combination.

[0097] It is also advantageous if the support and / or the form includes at least one ventilation section, in particular a vent slope. A ventilation section allows air to escape during the insulation process, which improves the homogeneity of the insulation material.

[0098] It is advantageous if two holding sections of the receiving groove are separated from each other by at least one recess. This separation allows for more precise positioning of the conductor and improves the electrical insulation in the area of ​​these recesses.

[0099] It is also advantageous if the support includes a base plate, with the retaining sections preferably projecting from the base plate along the vertical direction. The base plate provides a stable foundation for the support and facilitates handling during production. 23 SMS-11226a-24

[0100] August 27, 2025

[0101] It is advantageous if the support includes at least one stiffening element and / or at least one additional groove for the stiffening element. Stiffening elements increase the mechanical strength of the support and ensure the long-term stability of the inductive charging unit.

[0102] Furthermore, an inductive charging unit is proposed. Preferably, the inductive charging unit and / or the flat coil and / or the support are manufactured according to the method described above, wherein the aforementioned features may be present individually or in any combination. The inductive charging unit is preferably designed for the inductive charging of an electrical energy storage device, for example, in a motor vehicle. The inductive charging unit preferably comprises at least one electrical conductor with which a magnetic field can be generated, and / or a casing with which the electrical conductor can be encased.

[0103] Preferably, the inductive charging unit comprises at least one carrier as described above, wherein the aforementioned features may be present individually or in any combination. Additionally or alternatively, the carrier and / or the electrical conductor is, in particular, completely and / or seamlessly encased by the shell. Additionally or alternatively, the carrier material and the insulating material of the shell are identical. Using identical materials for the carrier and shell can simplify manufacturing and ensure material compatibility. Additionally or alternatively, the carrier material and / or the insulating material is an electrically and / or thermally insulating plastic, in particular a thermoplastic, and / or a resin, in particular a synthetic resin. These materials offer excellent insulating properties and are resistant to high temperatures and mechanical stress.Additionally or alternatively, the electrical conductor and / or at least one functional element is completely and / or entirely surrounded by the carrier material and / or the insulating material. Additionally or alternatively, the electrical conductor is at least 24 SMS-11226a-24.

[0104] 27.08.2025 partially covered by a coat and / or provided with the coat.

[0105] Additionally or alternatively, the inductive charging unit includes at least one functional element as described above.

[0106] It is also advantageous if the inductive charging unit includes an encapsulation, wherein the encapsulation preferably at least partially encloses and / or surrounds the casing. Additionally or alternatively, the casing is preferably at least partially integrated and / or embedded within the encapsulation. The additional encapsulation protects the underlying components from mechanical stress, moisture, and / or chemical media, in addition to or as an alternative to the casing. This increases the overall service life of the charging unit and ensures reliable operation under demanding environmental conditions. The encapsulation can be made, for example, of a road-compatible material, in particular bitumen, polymer-modified bitumen, rubber, and / or asphalt, and / or of a plastic, in particular polyester, HDPE, TPU, polyamide, and / or fiber-reinforced plastic.

[0107] Preferably, the encapsulation comprises at least one and / or two activatable surfaces. The activatable surface can include an activatable adhesive and / or melt. This allows the inductive charging unit to be bonded to the road surface more effectively and / or easily.

[0108] It is also advantageous if the encapsulation can be applied in a single extrusion step and / or comprises a road-compatible material, in particular bitumen, polymer-modified bitumen, and / or asphalt. Application via extrusion enables continuous production at high process speeds. The use of a road-compatible material ensures that the inductive charging unit adapts mechanically and / or thermally to the road surface structure and / or bonds with it. The encapsulation is preferably designed as a media-resistant encapsulation, so that internal components of the inductive 25 SMS-11226a-24

[0109] August 27, 2025

[0110] The charging unit is protected from external influences such as liquids, water, or oil. Additionally or alternatively, the encapsulation can improve the connection to the road surface. For example, the encapsulation can comprise a road-like material, such as polymer-modified bitumen. A material-compatible design reduces thermomechanical stresses between the charging unit and the road surface. This facilitates integration into existing road construction systems and extends maintenance intervals.

[0111] Advantages arise when the form for the feeding step is provided as a casting mold and / or is formed by the capsule material itself. In the latter case, inserting the part into the mold and closing the mold are unnecessary, as this is done automatically by closing the capsule. However, in this variant, the feeding step occurs during or after the capsuleing step. Using a casting mold ensures precise component geometry and / or repeatable production. If the form is created directly by the capsule material, separate mold tools can be dispensed with, saving material and / or process time.

[0112] Additionally or alternatively, the encapsulation is at least partially inserted into the mold. This allows the insulating material to be applied directly to the encapsulation (and not to the mold).

[0113] This can, for example, simplify the demolding process and / or protect the mold. Additionally or alternatively, it is advantageous if the encapsulation is multi-part, particularly two-part. Additionally or alternatively, the encapsulation, particularly a first encapsulation section, can be inserted into the mold. The support, support sections, electrical conductor, and / or the at least one functional element can be inserted, placed, and / or wound into the first encapsulation section. The insulating material can then be added. Optionally, a second encapsulation section can then be used to encapsulate the support, support sections, electrical conductor, and / or the at least one functional element and / or the outer shell. 26 SMS-11226a-24

[0114] August 27, 2025

[0115] The features of the inductive charging unit described above and / or below can be used independently of each other and / or in any combination.

[0116] It is advantageous if the inductive charging unit, especially one without fixings and / or with thermal conductivity, is installed in the road surface. The fixing-free design allows for quick and easy installation of the flat coil in the road surface. This reduces installation costs and simplifies maintenance. The thermal conductivity of the flat coil helps dissipate the heat generated during the charging process, increasing energy transfer efficiency and preventing overheating damage.

[0117] Further advantages of the invention are described in the following exemplary embodiments. These show:

[0118] Figures 1 to 3 show a schematic side view of a device for manufacturing an inductive charging unit according to an exemplary embodiment.

[0119] Figures 4 to 6 show a schematic side view of a device for manufacturing an inductive charging unit according to an alternative embodiment, and

[0120] Figure 7 shows a schematic top view of a support according to an exemplary embodiment.

[0121] In the following description of the figures, the same reference symbols are used for features that are identical and / or at least comparable in the different figures. The individual features, their design and / or mode of action are usually only explained in detail upon their first mention. If individual features are not mentioned again, see 27 SMS-11226a-24.

[0122] As explained in detail on 27.08.2025, their design and / or mode of operation corresponds to the design and mode of operation of the already described equivalent or identically named features.

[0123] Figures 1 to 3 each show a schematic side view of a device 1 for manufacturing an inductive charging unit 2 according to an exemplary embodiment. Figures 1 to 3 each show different process steps of a method for manufacturing an inductive charging unit 2. Figure 1 shows, in particular, the insertion of an electrical conductor 3 into a mold 5.

[0124] The device 1 comprises a laying unit 9, which serves to insert the electrical conductor 3 into the mold 5. During insertion into the mold 5, the electrical conductor 3 is wound spirally, thereby forming a flat coil 4. In the illustrated embodiment, the electrical conductor 3 is wound into the mold 5 by means of a free-bending step, in particular freely and / or without a support and / or independently of a support.

[0125] The method for manufacturing an inductive charging unit 2 comprises inserting an electrical conductor 3 into a mold 5 and supplying an insulating material to the mold 5. The supply of the insulating material is shown in Figure 2. During insertion, the electrical conductor 3 is wound spirally, forming at least two conductor turns. These conductor turns are preferably arranged within a winding plane. These conductor windings are not visible in the side view shown here; therefore, reference is made to Figure 7, which shows a top view of a receiving groove 17 of a carrier 6 in the form of these windings.

[0126] According to Figure 1, the device 1 can comprise a mold base 12 of the mold 5 into which the electrical conductor 3 is inserted. The mold 5 is simultaneously the subsequent injection mold. For routing the electrical 28 SMS-11226a-24

[0127] August 27, 2025

[0128] To form conductor 3 into conductor loops and / or to produce the flat coil 4, the mold 5, in particular the mold base 12, and / or the laying unit 9, in particular the laying head 10, is moved. For this purpose, the device 1, in particular the laying unit 9, comprises a movement device 41 in the illustrated embodiment. With the aid of the movement device 41, the laying head 10 can be moved along a first axial direction A1 and / or a second axial direction A2 in the illustrated embodiment. In this way, the electrical conductor 3 can be laid in a targeted and / or free manner. As already mentioned, the mold base 12 can additionally or alternatively be moved, for example with the aid of a mold carrier 39 of the device 1.

[0129] The device 1 also includes a control unit 38 for controlling the device 1 according to the described method. Preferably, the control unit 38 is designed as a CNC control unit, so that it controls the device 1 to carry out the aforementioned free-bending step.

[0130] In the illustrated embodiment, the electrical conductor 3 is provided with a sheath 13, which is heated before and / or during the winding of the electrical conductor 3, so that the electrical conductor 3 with the sheath 13 is bendable. For this purpose, the device 1, in particular the laying unit 9 and / or the laying head 10, comprises a conductor heater 43 in the illustrated embodiment. The conductor heater 43 heats the sheath 13 of the electrical conductor 3 such that it is more easily bendable. To fix the electrical conductor 3 within the mold 5, the sheath 13, which is designed in particular as a plastic sheath and / or thermoplastic sheath, can be cooled after winding and / or before the second feeding step. Cooling fixes the electrical conductor 3 in place. However, it is also conceivable that the electrical conductor 3 can be arranged, or can be arranged, in a dimensionally stable and / or fixed position in the mold after winding, even without the sheath 13.29 SMS-11226a-24.

[0131] 27.08.2025

[0132] Preferably, the electrical conductor 3 is fixed at at least one conductor end 14. This allows the conductor end 14 to be used for subsequent contacting. In the illustrated embodiment, the conductor end 14 is fixed during and / or after winding by means of a clamping device 15. The clamping device 15 is considered an integral part of the device 1, which is designed to clamp and thereby fix the conductor ends 14. Different conductor levels and / or conductor loops can be separated and / or insulated from each other by means of a reinforcing element 24. The reinforcing element 24 can, for example, be designed as an insulating material, in particular as a sandwich insulating material, and thus additionally or alternatively ensure the electrical separation of the conductor levels of the electrical conductor 3.Such insulation can be advantageous, for example, when contacting the at least one conductor end 14 with the at least one functional element 20, 21, 22, 23. Additionally or alternatively, the sheath 13 can fulfill the function of the reinforcing element 24 and / or the clamping device 15.

[0133] Figure 1 also shows that the electrical conductor 3 is inserted into the mold base 12. Additionally, it is advantageous if at least one functional element 20, 21, 22, 23, in particular a capacitor 20, an interface 21, a monitoring device 22 and / or a computing device 23, is inserted into the mold 5, in particular the mold base 12.

[0134] The embodiment shown in Figure 1 further illustrates that the electrical conductor 3 and / or the conductor windings formed from the electrical conductor 3 are held in place by a retaining element 26 after being inserted into the mold 5. Similar to the sheath 13, the retaining element 26 serves to ensure and / or assist in fixing the electrical conductor 3 as a flat coil. However, it is conceivable that the electrical conductor 3 can be fixed in the mold 5, particularly the mold base 12, without the sheath 13 and / or without the retaining element 26. Thus, the electrical conductor 3 can be fixed in the mold 5, particularly without the mold base 12. (30 SMS-11226a-24)

[0135] August 27, 2025

[0136] For example, conductor 3 must be made of a material that possesses this property.

[0137] As shown in Figure 1, the mold 5 includes a locking mechanism 29, by means of which a mold lid 19 (see Figure 2) can be connected to and / or locked to the mold base 12. The mold 5 may also include a seal 30 for subsequent sealing. Additionally or alternatively, the mold 5 includes a coating (not shown) that facilitates demolding of the inductive charging unit 2 after manufacture.

[0138] The embodiment shown in Figure 1 illustrates that the device 1, in particular the laying unit 9, comprises the laying head 10 for laying the electrical conductor 3 in the mold 5. The laying head 10 is equipped with a roller, a funnel, and / or a pressure element 49, preferably designed as a pressure roller. The device 1 further comprises the mold carrier 39 for receiving the mold 5 and / or the mold base 12. As described, the mold carrier 39 can be moved to facilitate the laying of the electrical conductor 3. Additionally or alternatively, the mold carrier 39 can be a conveyor belt, which enables the inductive charging unit 2 to be manufactured using flow production or assembly line production.

[0139] Additionally or alternatively, the device 1 in the illustrated embodiment comprises a conductor feed 40 for supplying the electrical conductor 3 to the laying head 10, wherein the supply can be controlled as required by the control unit 38. Furthermore, the device 1 in the illustrated embodiment comprises a disconnecting device 42 with the aid of which the electrical conductor 3 can be disconnected and, for example, at least one conductor end 14 can be produced.

[0140] Furthermore, Figure 1 indicates that an encapsulation 50 is inserted into the mold 5. The encapsulation 50 can, for example, consist of a 31 SMS-11226a-24

[0141] 27.08.2025 The encapsulation may be made of roadway-compatible material, in particular bitumen, polymer-modified bitumen, rubber and / or asphalt, and / or of a plastic, in particular polyester, HDPE, TPU, polyamide and / or fiber-reinforced plastic. Preferably, the encapsulation 50 comprises at least one and / or two activatable surfaces. The activatable surface may comprise an activatable adhesive and / or melt.

[0142] Following the process step shown in Figure 1, the electrical conductor 3, in the form of a flat coil 4, is inserted into the mold 5, in particular the mold base 12 and / or the encapsulation 50. Furthermore, the at least one functional element 20, 21, 22, 23 is inserted into the mold 5 and / or encapsulation 50. Additionally or alternatively, the contacting has already been carried out.

[0143] The mold 5 is then closed with the mold lid 19. This process step is shown in Figure 2. The mold 5 includes, particularly in the area of ​​the mold lid 19, a material feed 25, which in the illustrated embodiment can be used for the insulating material and is preferably openable and closable. Thus, the insulating material for producing the casing 11 (fully shown in Figure 3) can be supplied to the interior 27 of the mold 5 by means of the material feed 25.

[0144] Additionally or alternatively, it is conceivable that a part and / or encapsulation section of the encapsulation 50 can be inserted into the mold lid 19. It is also conceivable that the mold 5, the mold lid 19, and / or the mold base 12 are at least partially provided by the encapsulation 50. This would allow the mold 5, the mold lid 19, and / or the mold base 12 to be omitted and / or designed in a more delicate manner. Additionally or alternatively, this could reduce the stress and / or load on the mold 5, the mold lid 19, and / or the mold base 12.

[0145] Figure 2 also shows a further process step in which the mold 5 and / or the material feed 25 for the insulation material is moved, in particular tilted and / or pivoted. The mold 5 is preferably 32 SMS-11226a-24

[0146] On August 27, 2025, after movement, in particular pivoting, the mold 5 is held in the inclined position shown here. During and / or after the feeding of the insulation material, a venting step is thereby carried out. The device 1 preferably comprises a venting device 32 and / or a venting opening 31 for this purpose. The venting device 32 is preferably designed as a tilting or pivoting device, with the aid of which the mold 5 can be tilted and / or pivoted. For example, the mold 5 and / or, as shown in the embodiment of Figure 2, the mold carrier 39 of the device 1 can be tilted. The air can then flow out through the venting opening 31 due to the inclined position. This improves the filling of the mold 5 with the insulation material.

[0147] The device 1 further preferably comprises a temperature control unit 34, which serves to carry out the temperature control step. During the feeding step, at least one temperature control step is performed, in which preferably the electrical conductor 3 and / or, as shown in the illustrated embodiment, the mold 5 is heated, tempered, and / or a curing temperature is maintained. The curing of the casing 11 can be improved and / or accelerated by means of temperature control. Preferably, the temperature control takes place only after the interior 27 has been completely filled with the insulating material.

[0148] The embodiment shown in Figure 2 further demonstrates that the retaining element 26 is removed from the interior 27 of the mold 5 after the insulating material has been added and / or during the venting step and / or before and / or during the tempering step. One of the retaining elements 26 from Figure 1 has already been completely removed, and the second retaining element 26 has been partially removed, from the interior 27. This simplifies the complete encasing of the electrical conductor 3. The removal of at least one retaining element 26 can be accomplished using the slide mechanism technology known from the prior art, which is described in 33 SMS-11226a-24.

[0149] 27.08.2025 primarily for the production of undercuts or undercuts, will be ensured.

[0150] As can be seen, the mold lid 19 and the mold base 12 were locked and / or secured to each other by means of the locking mechanism 29. During assembly, the seals 30 were compressed so that no insulating material can escape from the interior 27 of the mold 5 between the mold lid 19 and the mold base 12. It is also conceivable that the mold 5 comprises further mold sections, which could, for example, be used to produce more complex shells 11.

[0151] Following the complete filling of the mold 5, the shell 11 is cured by tempering, as previously described. Once the shell 11 is completely and / or at least dimensionally stable, it is removed from the mold 5. For this purpose, the mold lid 19 is preferably removed. The electrical conductor 3 is now preferably completely and / or seamlessly encased by the insulating material and / or surrounded by the shell 11 formed from the insulating material. This process step is illustrated in Figure 3. After demolding and / or, alternatively to the method shown here, during tempering, the inductive charging unit 2 is tested. For this purpose, the device 1 in the illustrated embodiment includes a test device 35. This allows a functional test to be performed, in which the function of the at least one electrical conductor 3 and / or the at least one functional element 20, 21, 22, 23 is checked.

[0152] As already indicated above, the insulating material can be at least partially applied to the encapsulation 50 inserted into the mold 5. This can, for example, simplify the demolding process and / or protect the mold 5. In the finished state of the inductive charging unit 2, the shell 11 can thus provide the electrical and / or thermal and / or fluid-tight insulation. 34 SMS-11226a-24

[0153] August 27, 2025

[0154] Encapsulation 50 is preferably responsible for the mechanical stability of the inductive charging unit 2. In particular, encapsulation 50 makes it conceivable, for example, that the inductive charging unit 2 can be placed above and / or on the roadway when used as a roadway charging unit.

[0155] The inductive charging unit 2 is now complete and can be used, for example, to charge an electrical energy storage device, such as that of an electric vehicle. For example, the inductive charging unit 2, in particular without fixing agents and / or thermally conductive, can be arranged in a roadway and / or encased in ferritic concrete and / or encompass the ferritic concrete.

[0156] Figures 4 to 6 show a schematic side view of a device 1 for manufacturing an inductive charging unit 2 according to an alternative embodiment. The device 1 can preferably be used to carry out an alternative method for manufacturing the inductive charging unit 2.

[0157] In a first process step, a support 6 for the electrical conductor 3 is provided. Figure 4 shows, by way of example, the production of the support 6, wherein the support 6 is preferably produced at least partially in the mold 5. For this purpose, the mold 5 comprises a support mold lid 28. The mold base 12 of the mold 5 is preferably designed as a common mold base 12, so that it can serve both for the production of the support 6 and for the production of the casing 11 (see similarly Figure 3). As an alternative to the embodiment shown in Figure 4, the support 6 can be produced beforehand and / or otherwise, for example as a deep-drawn part.

[0158] As mentioned above, in the embodiment shown in Figure 4, the support 6 is manufactured. For this purpose, a support material is fed into the mold 5, which comprises the mold base 12 and the support mold lid 28. This 35 SMS-11226a-24

[0159] August 27, 2025 can be described as the first feeding step. Similar to the embodiment shown in Figure 2, the venting step could also be carried out during carrier production, in particular with the venting device 32 and / or the venting opening 31 (see Figure 2). The temperature control step using the temperature control device 34 shown in Figure 2 would also be conceivable.

[0160] Figure 5 shows the insertion and / or winding of the electrical conductor 3 into the mold 5. In contrast to the embodiment shown in Figures 1 to 3, the electrical conductor 3 is inserted into the carrier 6. As already described, the carrier 6 can be produced by the first feeding step according to Figure 4 or inserted into the mold 5.

[0161] The device 1, in particular the laying unit 9, is designed similarly to the embodiment shown in Figure 2. The difference here is that the electrical conductor 3 is not sheathed by the casing 13. However, it is conceivable that the electrical conductor 3, together with the casing 13, could also be inserted into the carrier 6.

[0162] The electrical conductor can be inserted into the support 6 using the laying unit 9. The support 6 preferably comprises at least one retaining section 16 and / or at least one receiving groove 17 for holding the electrical conductor 3.

[0163] As shown in Figure 5, the support 6 is designed for an inductive charging unit 2 and / or a flat coil 4. An electrical conductor 3 of the inductive charging unit 2 and / or the flat coil 4 can be received and / or fixed using the support 6. The support 6 has a receiving groove 17, open along a vertical direction HR of the support 6 and spirally shaped, for receiving the spiral electrical conductor 3.

[0164] The recording groove 17 is interrupted by at least one recess 44. This allows for a separation between the at least one recess 44 of the 36 SMS-11226a-24

[0165] August 27, 2025

[0166] Between the support 6 and the integrated electrical conductor 3, at least one cavity 7 for an insulating material of the inductive charging unit 2 is formed along the vertical direction HR of the support 6 and / or along a radial direction RR of the support 6 and / or the flat coil 4 on both sides of the electrical conductor 3. An integrated electrical conductor 3 can thus be spaced apart from the support 6 in the area of ​​the recess 44, for example, along the vertical direction HR and / or radial direction RR.

[0167] As shown in Figure 5, the support 6 comprises a base plate 46, wherein the retaining sections 16 preferably project from the base plate 46 along the vertical direction HR and / or the receiving groove 17 is configured within the base plate 46. To stiffen the support 6 and / or the inductive charging unit 2 produced therefrom, the support 6 comprises at least one stiffening element 47 and / or at least one additional groove 48 for the stiffening element 47. With the aid of a positioning device 37 of the device 1, the at least one functional element 20, 21, 22, 23 and / or the at least one stiffening element 47 can be inserted into the mold 5, in particular into the mold base 12, and / or positioned within the mold 5.

[0168] As can be seen from Figure 5, the device 1 comprises at least one fixing device 33 for fixing the carrier 6 in the mold 5. This is done, for example, by a surface suction against the mold 5. The carrier 6 is held within the mold 5, in particular mechanically and / or with the aid of a vacuum.

[0169] To enable the carrier 6 to be connected to the insulation material following the winding step shown here, a connection surface 18 of the carrier 6 can be prepared. For this purpose, the device 1 in the illustrated embodiment comprises a preparation unit 36, with the aid of which the connection surface 18 can be chemically and / or physically prepared and / or processed. This preparation unit 36 ​​comprises 37 SMS-11226a-24

[0170] 27.08.2025 preferably an application agent for the plasma and / or a nozzle for the adhesion promoter. In addition to or alternatively to preparing the bonding surface 18, a curing time of the carrier material can be reduced between a first feeding step or the insertion step according to Figure 4 and the second feeding step according to Figure 6. Thus, the carrier 6 may not yet be fully cured when the insulating material is fed in.

[0171] This second feeding step is shown in Figure 6. In this second feeding step, the mold lid 19 of the mold 5 is preferably connected to the mold base 12. Using the material feed 25, the insulating material for producing the sheath 11 can be fed into the interior 27 of the mold 5, similar to the embodiment shown in Figure 2. In this second feeding step, the electrical conductor 3 is at least partially encased. As can be seen in Figure 6, the cavity 7 provided by the recess 44 is also filled with the insulating material, so that the electrical conductor 3 is completely encased by the insulating material, or the sheath 11 formed therefrom, in the area of ​​the cavity 7.

[0172] The insulating material supplied in the second feeding step is preferably an electrically and / or thermally insulating plastic, in particular a thermoplastic, and / or resin, in particular a synthetic resin. Additionally or alternatively, the carrier material of the support 6 and the insulating material of the casing 11 are identical or similar, so that they can be completely and / or seamlessly joined at the connection surface 18. The preparation step and / or the shortened curing time ensure the most reliable possible material-bonded connection.

[0173] As an alternative to the method shown here, it would also be conceivable that the support 6 and the electrical conductor 3 contained in the support 6 are completely and / or seamlessly encased by the shell 11. For example, the support 6 could be secured using retaining elements 26 38 SMS-11226a-24

[0174] On August 27, 2025, the form 5 will be inserted completely spaced apart. This would allow for complete encasing of the support 6 and the electrical conductor 3 by the casing 11.

[0175] Figure 7 shows a schematic top view of a support 6 according to an embodiment. The support 6 is designed to be used for one of the devices 1 and / or for one of the methods according to the previous embodiments, preferably for the device 1 according to the embodiment shown in Figures 4 to 6. Thus, the support 6 of the embodiment shown in Figures 4 to 6 is preferably designed similarly to the support 6 in Figure 7.

[0176] The embodiment shown in Figure 7 depicts the support 6 with the base plate 46, the receiving groove 17, and / or the at least one retaining section 16. The electrical conductor 3 is already partially inserted into the receiving groove 17. For example, the support 6 shown here could be inserted into the device 1 and / or into the form 5 according to the embodiment shown in Figure 5. Preferably, the receiving groove 17 is interrupted by the at least one recess 44, such that the recess 44 separates two retaining sections 16 from each other. This is illustrated by way of example in Figure 7 at one recess 44.

[0177] Similar to the embodiment shown in Figures 5 and 6, the at least one recess 44 can also form a cavity 7. Additionally or alternatively, the support 6 is porous and / or designed as a foam with at least one cavity 7. If the support 6 is porous and / or designed as a foam, the recesses 44 can be omitted or additional cavities 7 can be formed. If the support 6 is porous and / or designed as a foam, the insulating material of the inductive charging unit 2 (see Figures 5 and 6) can at least partially penetrate the support. 39 SMS-11226a-24

[0178] August 27, 2025

[0179] Furthermore, in the illustrated embodiment, the support 6 comprises at least one venting section 45, which is preferably designed as a vent slope. If the support 6 shown here is received in the device 1 according to Figure 6, the at least one venting section 45 can assist in venting the interior 27 of the mold 5. The mold 5 of Figure 6 preferably comprises similar venting sections 45 and / or the side walls are similarly designed.

[0180] Furthermore, the support 6 of the embodiment shown in Figure 7 demonstrates that the receiving groove 17 comprises several groove sections spaced apart from each other along the radial direction RR of the support 6 by a distance 8a, 8b. The received electrical conductor 3 will also encompass these distances 8a, 8b.

[0181] These distances 8a, 8b can preferably vary. For example, in the illustrated embodiment, the support 6 comprises several distances 8a, 8b. In the illustrated embodiment, the distances 8a, 8b increase outwards along the radial direction RR. Thus, the embodiment shown in Figure 7 depicts the support 6 with at least one first distance 8a and one second distance 8b. The first distance 8a is selected to be larger than the second distance 8b. During winding (see Figure 6), this distance 8a, 8b between the conductor turns and / or groove sections can be made adjustable, adaptable, and / or changeable using the laying unit 9. As shown, in addition to the first distance 8a and the second distance 8b described, the support 6 can also include a third distance not designated by reference numerals.

[0182] It should be noted that the support is not strictly necessary for creating the distance 8a, 8b. Additionally or alternatively, the device can include the control unit shown in Figures 1 to 6 as a CNC control. This control unit is preferably designed such that the laying unit 9 realizes and / or produces the variable distance 8a, 8b. 40 SMS-1 1226a-24

[0183] August 27, 2025

[0184] Furthermore, it should be noted that the preceding description of the figures combines various features and / or process steps by way of example. However, it is possible to use individual features and / or process steps independently of the described combination and / or in other combinations. In particular, it is conceivable to use the additional or alternative embodiments of the independent claims on their own and / or independently of the described combination and / or in other combinations.

[0185] 41 SMS-1 1226a-24

[0186] August 27, 2025

[0187] List of reference signs

[0188] Device inductive charging unit electrical conductor flat coil shape carrier cavity a, 8b distance

[0189] Laying unit 0 Laying head 1 Sleeve 2 Molded base 3 Sheath 4 Conductor end 5 Clamping device 6 Holding section 7 Receiving groove 8 Connecting surface 9 Molded cover 0 Capacitor 1 Interface 2 Monitoring device 3 Computing device 4 Reinforcing element 5 Material feed 6 Holding element 7 Interior 8 Carrier molded cover 9 Locking mechanism 42 SMS-1 1226a-24

[0190] 27.08.2025 0 Seal 1 Vent opening 2 Venting device 3 Fixing device

[0191] 34 Temperature control unit

[0192] 35 Testing equipment

[0193] 36 Processing unit

[0194] 37 Positioning device

[0195] 38 Control

[0196] 39 mold carriers

[0197] 40 ladder feed

[0198] 41 Movement device

[0199] 42 Separating device

[0200] 43 Ladder heating

[0201] 44 Exclusion

[0202] 45 Ventilation section

[0203] 46 Base plate

[0204] 47 Stiffening element

[0205] 48 additional groove

[0206] 49 Pressure element

[0207] 50 capsules

[0208] HR High Alignment

[0209] RR Radial direction

[0210] A1 first axial direction

[0211] A2 second axial direction

Claims

1 SMS-1 1226a-24 August 27, 2025 Patent claims 1. Method for manufacturing an inductive charging unit (2) in which at least one electrical conductor (3) is placed in a mold (5) and an insulating material is subsequently supplied to the mold (5), characterized in that - that the electrical conductor (3) is wound spirally during insertion into the mold (5), and / or - that in a first feeding step a carrier material is fed into the form (5) to produce a carrier (6) for the electrical conductor (3) and in a second feeding step the insulating material is fed to at least partially encase the electrical conductor (3), and / or - that the support (6) and the electrical conductor (3) held spirally by the support (6) are completely and / or seamlessly encased by the insulating material, and / or - that the insulating material is supplied to at least one cavity (7) formed within the support (6) and / or between the support (6) and the electrical conductor (3) held spirally by the support (6), and / or - that a venting step is carried out before and / or during and / or after the supply of the insulating material.

2. Method according to the preceding claim, characterized in that the electrical conductor (3) is wound into the form (5) by means of a free bending step, in particular freely and / or without support and / or independently of the support.

3. Method according to one of the preceding claims, characterized in that at least two conductor turns are formed when winding the electrical conductor (3), 2 SMS-1 1226a-24 27.08.2025 wherein preferably the, in particular all, conductor windings are arranged within a winding plane, so that a flat coil (4) is formed.

4. Method according to one of the preceding claims, characterized in that the electrical conductor (3), in particular during a free bending step, can be wound with a radial distance (8a, 8b) between the several conductor windings, wherein preferably during winding the distance (8a, 8b) between the conductor windings is set, adjusted and / or changed so that a variable distance (8a, 8b) of the conductor windings can be produced and / or realized.

5. Method according to one of the preceding claims, characterized in that when winding the electrical conductor (3) the form (5), in particular a form base (12) of the form (5), and / or the laying unit (9), in particular the laying head (10), is moved.

6. Method according to one of the preceding claims, characterized in that a sheath (13), in particular as a plastic sheath and / or thermoplastic sheath, of the electrical conductor (3) is heated before and / or during the winding of the electrical conductor (3) so that the electrical conductor (3) with the sheath (13) is bendable, wherein the sheath (13) is preferably fixed by cooling after the winding and / or before the second feeding step.

7. Method according to one of the preceding claims, characterized in that during winding and / or following the winding of the electrical conductor (3), in particular with the aid of a clamping device (15) and / or in the area of ​​at least one 3 SMS-1 1226a-24 August 27, 2025 The conductor end (14) is fixed and / or electrically insulated, in particular with the aid of a reinforcing element (24).

8. Method according to one of the preceding claims, characterized in that a connecting surface (18) of the carrier (6) is prepared, in particular physically and / or chemically, preferably before the second feeding step, and / or a curing time of the carrier material is not exceeded between the first feeding step and the second feeding step, so that the carrier (6) is not yet or not yet fully cured when the insulating material is fed in.

9. Method according to one of the preceding claims, characterized in that at least one tempering step is carried out before and / or during and / or after the supply of the insulating material and / or between the first supply step and the second supply step, in which preferably the carrier (6), the at least one electrical conductor (3) and / or the shape (5) is heated, tempered and / or a curing temperature is maintained.

10. Method according to one of the preceding claims, characterized in that before and / or during the venting step the mold (5) and / or a material feed (25) for the insulating material and / or the carrier material is moved, in particular tilted and / or pivoted, wherein after the feeding of the insulating material and / or before the tempering step and / or during the tempering step and / or after the tempering step and / or before removing the inductive charging unit (2) from the mold (5) a functional test of the at least one electrical conductor (3) and / or the at least one functional element (20, 21, 22, 23) is preferably carried out. 4 SMS-1 1226a-24 August 27, 2025 11. Method according to one of the preceding claims, characterized in that the at least one electrical conductor (3) and / or the conductor windings formed from the at least one electrical conductor (3) are held after being placed in the mold (5), in particular by means of at least one retaining element (26), for example the mold (5), wherein preferably the at least one retaining element (26) is removed from an interior (27) of the mold (5) after the supply of the insulating material and / or during the venting step and / or before the tempering step and / or during the tempering step.

12. Device (1) for manufacturing an inductive charging unit (2), comprising at least one mold (5) by means of which at least one carrier (6) of the inductive charging unit (2) and / or at least one shell (11) of the inductive charging unit (2) can be manufactured from a carrier material, characterized in that the device (1) comprises at least one routing unit (9) by means of which an electrical conductor (3) of the inductive charging unit (2) can be inserted into the at least one mold (5), and / or the mold (5) comprises a mold base (12) into which the electrical conductor (3) can be inserted and the insulating material can be supplied, and / or the device (1) comprises at least one venting device (32) and / or at least one venting opening (31).with the aid of which a venting step of the mold (5) can be carried out and / or the device (1) comprises at least one control (38) for controlling the device (1) according to the method of the preceding claims.

13. Device according to the preceding claim, characterized in that the device (1) comprises at least one fixing device (33) and / or one temperature control device (34) and / or one 5 SMS-1 1226a-24 August 27, 2025 test device (35) and / or a preparation device (36) and / or a positioning device (37) and / or a laying head (10) and / or a form carrier (39) and / or a conductor feed (40) and / or a movement device (41) and / or a clamping device (15) and / or a disconnecting device (42) and / or a conductor heating device (40).

14. Carrier (6) for an inductive charging unit (2) and / or a flat coil (4), in particular coil carrier and / or flat coil carrier, with the aid of which an electrical conductor (3) of the inductive charging unit (2) and / or the flat coil (4) can be received and / or fixed, with a receiving groove (17) open along a vertical direction (HR) of the carrier (6) and spirally shaped for receiving the spiral electrical conductor (3), characterized in that - that the spiral receiving groove (17) for several conductor turns of the electrical conductor (3) comprises several groove sections spaced apart from each other along a radial direction (RR) of the support (6) and / or the flat coil (5) by a distance (8a, 8b), wherein several of the distances (8a, 8b) are of different sizes, and / or - that the receiving groove (17) is interrupted by at least one recess (44) so ​​that at least one cavity (7) can be formed between the at least one recess (44) and the electrical conductor (3) to be received and / or - that the support (6) is porous and / or designed as a foam with at least one cavity (7) so that the support (6) is at least partially penetrable by an insulating material of the inductive charging unit (2) and / or a shell (11) of the inductive charging unit (2) formed from the insulating material can abut the electrical conductor (3) on both sides through the at least one cavity (7) at least sectionally along a radial direction (RR) and / or the vertical direction (HR). 6 SMS-1 1226a-24 August 27, 2025 15. Inductive charging unit (2), comprising at least one electrical conductor (3) with which a magnetic field can be generated, and with a casing (11) with which the electrical conductor (3) is sheathed, characterized in that - that the inductive charging unit (2) is manufactured according to a method according to the preceding claims 1 to 11, - that the inductive charging unit (2) comprises at least one carrier (6) according to the preceding claim 14, and / or - that the support (6) and / or the electrical conductor (3) is completely and / or seamlessly encased by the sheath (11), and / or - that a carrier material of the carrier (6) and an insulating material of the shell (11) are identical and / or - that the electrical conductor (3) is at least partially enclosed by a sheath (13).

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