Base module for an inductive vehicle charging system
The ground module design with an insulating top plate and galvanic decoupling of low-voltage and high-voltage assemblies addresses electrical hazards in inductive vehicle charging, ensuring safety and preventing high voltage exposure.
Patent Information
- Authority / Receiving Office
- WO · WO
- Patent Type
- Applications
- Current Assignee / Owner
- BRUSA ELEKTRONIK AG
- Filing Date
- 2025-11-10
- Publication Date
- 2026-05-15
AI Technical Summary
Inductive vehicle charging systems face risks of electrical hazards due to high magnetic fields causing metallic foreign objects to heat and potentially damage the ground module, leading to dangerous high voltage exposure.
A ground module with a housing featuring a top plate made of electrically insulating material, a high-voltage assembly with a main coil for inductive energy transfer, and a low-voltage assembly that is basic-insulated and galvanically decoupled from the high-voltage assembly, preventing unwanted current flow and electrical contact.
Enhances electrical safety by blocking current flow between low-voltage and high-voltage assemblies, preventing damage and dangerous high voltage exposure, while maintaining power and signal exchange.
Smart Images
Figure EP2025082438_15052026_PF_FP_ABST
Abstract
Description
[0001] Floor module for an inductive vehicle charging system
[0002] The invention relates to a ground module GPM for an inductive vehicle charging system, in particular for electric vehicles and hybrid vehicles.
[0003] Such inductive vehicle charging systems are well known in the prior art. These typically comprise a stationary ground module (GPM) mounted on the ground, connected to a power supply, and featuring a primary coil through which energy can be inductively transferred to a secondary coil of a vehicle module (GPM) located in the vehicle. The energy transferred to the vehicle module (GPM) can be used, for example, to charge an energy storage device (battery) located in the vehicle.
[0004] Such a ground module GPM typically has within its housing one or more low-voltage electrical assemblies NSBG and at least one high-voltage assembly HSBG, the latter in particular comprising the electrical control of the primary coil and the primary coil itself.
[0005] Due to the high magnetic field strengths generated by the primary coil, metallic foreign objects located in the immediate vicinity, especially on a surface of the housing of the GPM ground module, can experience strong heating, in extreme cases so intense that the heated foreign objects burn through the housing of the GPM ground module or the GPM ground module can be damaged by mechanical impact to such an extent that in both cases there may be a risk of access to potentially dangerous high voltage.
[0006] The object of the invention is to provide a ground module GPM that prevents such electrical risks.
[0007] The invention is defined by the features of the independent claims. Advantageous further developments and embodiments are the subject of the dependent claims.
[0008] Further features, applications, and advantages of the invention will become apparent from the following description and the explanation of an embodiment of the invention illustrated in the figure. BRUS 60522 DE
[0009] The problem is solved with a ground module GPM for an inductive vehicle charging system, wherein the ground module GPM has a housing with a top surface, the top surface being formed at least partially by a top plate made of an electrically insulating material, a high-voltage assembly HSBG is arranged in the housing, which includes at least one main coil which serves for inductive energy transfer through the electrically insulating top plate, and the ground module GPM is designed and configured to inductively transfer energy to a vehicle module CPM arranged in a vehicle by means of the main coil.
[0010] A floor module GPM according to the invention is characterized in that a low-voltage assembly NSBG is arranged in the housing, wherein at least one electrically conductive component of the low-voltage assembly NSBG is arranged directly below and / or in the top plate, electrically conductive parts of the housing are electrically grounded, and the low-voltage assembly NSBG is designed to be basic-insulated and / or galvanically decoupled from the high-voltage assembly HSBG.
[0011] The base insulation and / or galvanic decoupling advantageously prevents unwanted current flow between the low-voltage assembly (NSBG) and the high-voltage assembly (HSBG) of the ground module (GPM), particularly in cases where, for example, a highly heated metallic foreign object burns through the top plate or where mechanical damage to the top plate of the ground module (GPM) potentially allows electrical contact between the low-voltage assembly (NSBG) and the high-voltage assembly (HSBG). This unwanted current can be life-threatening and cause damage to equipment. A ground module (GPM) according to the invention thus provides optimal protection against access to dangerous high voltage and therefore increases the electrical safety of the ground module (GPM).
[0012] The basic insulation is advantageously achieved by a non-electrically conductive covering and / or coating of the current-carrying components of the low-voltage assembly NSBG and the high-voltage assembly HSPG.
[0013] In this context, "galvanic decoupling / isolation" refers to the interruption of the electrical current flow between the low-voltage module (NSBG) and the high-voltage module (HSPG), while still allowing the exchange of power or signals between them. The electrical current flow between the BRUS 60522 DE
[0014] The low-voltage (NSBG) and high-voltage (HSBG) modules of the ground module (GPM) are advantageously separated by electrically non-conductive coupling elements. With galvanic isolation, the electrical potentials of the low-voltage (NSBG) and high-voltage (HSBG) modules of the ground module (GPM) are advantageously separated from each other, and the circuits are advantageously potential-free from one another. Naturally, this separation must not be compromised elsewhere, for example, via grounding. Earth loop currents and cross-interference from one supply rail to the other are thus blocked, and protection against certain fault conditions (e.g., electrical short circuits) can be implemented.
[0015] Galvanic decoupling (functional isolation) is advantageously achieved by one or more isolating transformer(s).
[0016] The main coil of the high-voltage assembly HSBG is advantageously designed as a flat coil and arranged in the housing in such a way that the magnetic field generated by it for inductive energy transfer passes through the top plate of the GPM essentially on the top side.
[0017] The low-voltage assembly NSBG is advantageously a FOD sensor assembly BGFOD, which serves to detect foreign objects, particularly in the area of the top of the base module GPM, and / or an LOD sensor assembly BGLOD, which serves to detect living beings, particularly in the area of the top and / or in the vicinity of the base module GPM, and / or a fan assembly, which serves to ventilate the housing, and / or a receiver and / or transmitter assembly, which serves to receive and transmit data.
[0018] Corresponding FOD sensor assemblies BGFOD (FOD = English for “Foreign Object Detection”), as well as LOD sensor assemblies BGLOD (LOD = English for “Living Object Detection”), as well as fan assemblies and receiver and / or transmitter assemblies are known in the prior art, to which reference is made here.
[0019] The HSBG high-voltage assembly is advantageously operated at a voltage in the range of 350 V to 8000 V.
[0020] The low-voltage module NSBG is advantageously operated with a voltage in the range of 1 V to 100 V. BRUS 60522 DE
[0021] In an advantageous further development of the ground module GPM, the electrically conductive component of the low-voltage assembly NSBG is a sensor, an antenna or an antenna array.
[0022] In an advantageous further development of the ground module GPM, the electrically conductive component of the low-voltage assembly NSBG is a fan and / or its housing.
[0023] In an advantageous further development of the ground module GPM, the electrically conductive component of the low-voltage assembly NSBG is an evaluation electronics unit and / or its housing.
[0024] In a further development of the ground module GPM, several low-voltage assemblies NSBG are present in the housing, each of which is separately basic-insulated and / or galvanically decoupled from the high-voltage assembly HSBG.
[0025] An advantageous further development of the ground module GPM is characterized by the fact that the one or more low-voltage assembly(s) NSBG are each arranged in a separate first housing within the housing, wherein the first housing(s) are each separately basic-insulated and / or galvanically decoupled from the high-voltage assembly HSBG.
[0026] An advantageous further development of the ground module GPM is characterized by the fact that the high-voltage assembly HSBG is arranged within the housing in a separate second housing, wherein the second housing is separately basic-insulated and / or galvanically decoupled from the low-voltage assembly(s) NSBG and / or their first housings.
[0027] Another aspect of the invention relates to an inductive charging system for vehicles with a floor module GPM, as described above, wherein the floor module GPM is designed and configured to inductively transfer energy to a second main coil of a vehicle module GPM arranged in a vehicle.
[0028] Further advantages, features, and details will become apparent from the following description, in which – possibly with reference to the drawing – at least one embodiment is described in detail. BRUS 60522 DE
[0029] It shows:
[0030] Fig. 1 shows a highly schematic cross-section through a floor module GPM 100 according to the invention.
[0031] Fig. 1 shows a highly schematic cross-section through a ground module GPM 100 of an inductive charging system according to the invention, wherein the ground module GPM 100 has a housing 101 with a top surface 102, the top surface 102 being formed at least partially by a top plate 103 made of an electrically insulating material, and a high-voltage assembly HSBG 104 is arranged in the housing 101, which in this case comprises a main coil and power electronics. The main coil serves for inductive energy transfer through the top plate 103, in particular for energy transfer to a second main coil of a vehicle module CPM arranged in a vehicle, e.g. for charging a vehicle battery.
[0032] The electrically conductive parts of housing 101 are electrically grounded.
[0033] The GPM 100 base module further comprises a low-voltage assembly NSBG 105 in housing 101, in this case, for example, a FOD sensor and / or an LOD sensor and / or a fan, wherein at least one electrically conductive component of the low-voltage assembly NSBG 105 is arranged directly below and / or in the top plate 103. The low-voltage assembly NSBG 105 is controlled and supplied with electrical energy by a controller.
[0034] The low-voltage assembly NSBG 105 is designed to be basic-insulated and galvanically decoupled (galvanic isolation) from the high-voltage assembly HSBG 104.
[0035] The high-voltage assembly HSBG 104 is operated here with a voltage in the range of 900 volts.
[0036] Although the invention has been further illustrated and explained in detail by means of preferred embodiments, the invention is not limited by the disclosed examples and other variations can be derived from them by a person skilled in the art without departing from the scope of protection of the invention. It is therefore clear that a multitude of possible variations exist. It is also clear that the examples mentioned in BRUS 60522 DE
[0037] The embodiments shown are merely examples and should not be interpreted in any way as limiting the scope of protection, the possible applications, or the configuration of the invention. Rather, the preceding description and the description of the figures enable the person skilled in the art to implement the exemplary embodiments in concrete terms. With knowledge of the disclosed inventive concept, the person skilled in the art can make numerous modifications, for example, regarding the function or the arrangement of individual elements mentioned in an exemplary embodiment, without leaving the scope of protection defined by the claims and their legal equivalents, such as a further explanation in the description.
[0038] BRUS 60522 DE
[0039] Reference symbol list
[0040] 100 GPM floor modules
[0041] 101 Housing of the GPM floor module
[0042] 102 Top of the case 101
[0043] 103 Top plate
[0044] 104 High-voltage assembly HSBG
[0045] 105 Low-voltage assembly NSBG
Claims
Patent claims 1. Ground module GPM (100) of an inductive vehicle charging system, wherein the ground module GPM has a housing (101) with a top surface (102), the top surface (102) being formed at least partially by a top plate (103) made of an electrically insulating material, a high-voltage assembly HSBG (104) is arranged in the housing (101) which comprises at least one main coil which serves for inductive energy transfer through the top plate (103), the ground module GPM (100) being designed and configured to inductively transfer energy to a vehicle module CPM arranged in a vehicle by means of the main coil, characterized in that a low-voltage assembly NSBG (105) is arranged in the housing (101), wherein at least one electrically conductive component of the The low-voltage assembly NSBG (105) is arranged directly below and / or in the top plate (103), electrically conductive parts of the housing (101) are electrically grounded, and the low-voltage assembly NSBG (105) is basic-insulated and / or galvanically decoupled from the high-voltage assembly HSBG (104).
2. Ground module GPM (100) according to claim 1, characterized in that the low-voltage assembly NSBG (105) is a FOD sensor assembly BGFOD, which serves to detect foreign objects in the area of the top of the ground module GPM (100) and / or is an LOD sensor assembly BGLOD, which serves to detect living beings in the area of the top (102) and / or in an environment of the The ground module GPM (100) serves and / or is a fan assembly that serves to ventilate the housing (101) and / or is a receiver and / or transmitter assembly that serves to receive and transmit data. BRUS 60522 DE 3. Ground module GPM (100) according to one of claims 1 to 2, characterized in that the high voltage assembly HSBG (104) is operated with a voltage in the range of 350 V to 8000 V.
4. Ground module GPM (100) according to one of claims 1 to 3, characterized in that the low voltage assembly NSBG (105) is operated with a voltage in the range of 1 V to 100 V.
5. Ground module GPM (100) according to one of claims 1 to 4, characterized in that the electrically conductive component of the low voltage assembly NSBG (105) is a sensor, an antenna or an antenna array.
6. Ground module GPM according to one of claims 1 to 4, characterized in that the electrically conductive component of the Low voltage assembly NSBG (105) is a fan and / or its housing.
7. Ground module GPM according to one of claims 1 to 4, characterized in that the electrically conductive component of the low voltage assembly NSBG is an evaluation electronics and / or its housing.
8. Ground module GPM according to one of claims 1 to 7, characterized in that several low-voltage assemblies NSBG (105) are present in the housing (101), each of which is separately basic-insulated and / or galvanically decoupled from the high-voltage assembly HSBG (104).
9. Ground module GPM according to one of claims 1 to 8, characterized in that the one or more low-voltage assembly(s) NSBG (105) are arranged within the housing (101) in a separate first housing, wherein the first housing(s) are each separately basic-insulated and / or galvanically decoupled from the high-voltage assembly HSBG (104). BRUS 60522 DE 10. Ground module GPM according to one of claims 1 to 9, characterized in that the one high-voltage assembly HSBG (104) is arranged within the housing (101) in a separate second housing, wherein the second housing is separately basic-insulated and / or galvanically decoupled from the low-voltage assembly(s) NSBG (104) and / or their first housings (106).
11. Inductive charging system for vehicles with a floor module GPM 100 according to one of claims 1 to 10, wherein the floor module GPM 100 is designed and configured to inductively transfer energy to a second main coil of a vehicle module GPM arranged in a vehicle.