Holding structure for receiving a wireless charging module

Abstract

The invention relates to a holding structure (6) for receiving a wireless charging module for charging a battery (5) of a vehicle (2) and / or for feeding a consumer of the vehicle (2) and / or for outputting energy from the battery (5) of the vehicle (2) and / or for outputting energy from an energy source of the vehicle (2), wherein the holding structure (6) has a frame (15) for receiving a wireless charging module (4) and mounting elements (7) for mounting the holding structure (6) on the vehicle (2).

Description

[0001] HOLDING RACK FOR HOLDING A WIRELESS CHARGING MODULE

[0002] The invention relates to a mounting frame for receiving a wireless charging module for charging a vehicle battery and / or for supplying power to a consumer of the vehicle and / or for supplying energy from the vehicle battery and / or for supplying energy from a vehicle energy source.

[0003] Electric vehicle batteries can be charged with alternating current (AC) or direct current (DC). Typical AC chargers can provide a charging power of up to 22 kW. AC charging systems can be divided into wired and wireless charging systems, with wireless charging systems primarily implemented as inductive charging systems (ICS). Wired AC chargers are usually integrated into electric vehicles and are also known as on-board chargers. An ICS typically consists of two separate modules, often referred to as the ground pad module (GPM) and the car pad module (CPM). The GPM is installed outside the electric vehicle, while the CPM is located inside the vehicle, usually on the underside.The electromagnetic interaction between the GPM and the CPM enables energy transfer from the GPM to the CPM and vice versa, and the CPM is then used to charge the electric vehicle's battery. Wireless charging systems are often more convenient for the user, as they typically require no manual intervention to start the battery charging process, other than placing the vehicle over the GPM.

[0004] A disadvantage of the vehicle-mounted wireless charging modules (CPMs) known from the prior art is that, due to their installation on the underside of an electric vehicle, they are relatively easily damaged, for example by stone chips or when the vehicle bottoms out on the road surface. Furthermore, movements and vibrations of the vehicle frame can lead to damage to the CPM. For example, unbalanced natural frequencies can lead to resonances and fractures. Due to differing technical specifications of platforms or manufacturers, vehicle frames can vary, which necessitates relatively complex and costly modifications to the respective CPMs.Furthermore, the electromagnetic compatibility (EMC) of CPMs typically requires additional shielding components, which, due to the often limited installation space in vehicles, presents additional challenges, especially since the space for connecting and disconnecting the CPM must also be considered. Finally, crash test requirements necessitate that CPMs exhibit a controlled breaking point preceded by an elastic phase followed by plastic deformation.

[0005] It is therefore the object of the invention to create a holding frame of the type mentioned above, which eliminates or at least mitigates the disadvantages mentioned above.

[0006] The problem is solved by a holding frame with the features of claim 1. Further preferred embodiments are described in the dependent claims.

[0007] The mounting bracket is designed to accommodate a wireless charging module for charging a vehicle battery and / or powering a vehicle component and / or supplying energy from the vehicle battery and / or supplying energy from a vehicle power source. The mounting bracket includes a frame for the wireless charging module and mounting elements for attaching the bracket to the vehicle.

[0008] Such a mounting frame provides mechanical stabilization for the vehicle-mounted wireless charging module (CPM). By allowing a certain degree of relative movement or displacement between the CPM and the vehicle body, the mounting frame acts as a kind of interface between the CPM and the vehicle body to absorb mechanical forces and protect the wireless charging module from deformation, impact, and damage.

[0009] In certain embodiments, the mounting elements are designed to create a detachable connection between the mounting frame and the vehicle. The detachable connection can be selected, in particular, from the group consisting of screwed, plugged, pinned, clipped, and glued connections.

[0010] In certain embodiments, the mounting elements are designed to create a positive-locking connection between the mounting frame and the vehicle. This positive locking ensures the connection between two interlocking connecting parts involved in force transmission, even without or with interrupted force transmission.

[0011] In embodiments, one or more of the mounting elements each have a suspension. The one or more mounting elements are flexibly connected to the frame by means of the suspension, the connection between the mounting element(s) and the frame being particularly elastic. In the context of the present connection, an "elastic connection" is understood to be a connection which is formed or provided by a material having a modulus of elasticity (Young's modulus) of at most 500 GPa.

[0012] In embodiments, the suspensions have a modulus of elasticity between 1 GPa and 500 GPa. Preferably, the suspensions have a modulus of elasticity in the range between 1 GPa and 80 GPa, more preferably between 1 GPa and 12 GPa, even more preferably between 1 GPa and 9 GPa, and even more preferably between 1 GPa and 3 GPa.

[0013] The stiffness or flexibility of the suspension is determined by its material and structure, which may include stiffening elements such as reinforcing ribs. The decisive factor is the stiffness of the suspension compared to the stiffness of the frame in conjunction with the wireless charging module. The suspensions can be made of materials such as plastic, fiber-reinforced plastic, polymer composites, metal alloys (especially light metal alloys), and combinations thereof. Alternatively or additionally, the frame can be made of plastic, fiber-reinforced plastic, polymer composites, metal alloys (especially light metal alloys), and combinations thereof.If the suspensions and the frame are made of the same material, the suspensions preferably have a different structure than the frame, resulting in lower stiffness or flexibility compared to the frame. This can be achieved, for example, by using a different number and / or arrangement of stiffening elements in the suspensions and in the frame.

[0014] In some embodiments, at least one mounting element includes a component for absorbing energy from relative movement between the vehicle and the support frame. This allows movements and vibrations of the vehicle frame to be effectively decoupled from the CPM (combined motion) absorbed within the frame.

[0015] In embodiments, particularly in which at least one mounting element includes an element for absorbing energy from relative movement between the vehicle and the support frame (described in more detail below), the suspensions have a modulus of elasticity between 20 GPa and 500 GPa. Preferably, the suspensions have a modulus of elasticity in the range of 20 GPa to 80 GPa. Since at least one of the mounting elements includes an element for absorbing energy from relative movement between the vehicle and the support frame, movements and vibrations of the vehicle frame no longer need to be primarily decoupled from the CPM (combined motion module) housed in the frame by the suspensions. In this case, the suspensions can have higher moduli of elasticity, which has a positive effect on the stability of the suspensions and / or the support frame.

[0016] In some embodiments, the energy-absorbing element features a frictional connection that transitions from a state of static friction to a state of sliding friction during relative movement. Elements comprising or consisting of an elastomer are particularly suitable for absorbing energy from relative movements between the vehicle and the mounting frame. Specifically, these elements can be rubber buffers or rubber bearings arranged on and / or within the mounting element.

[0017] In embodiments, at least one suspension has a predetermined breaking point. Providing such a structural weakness or predefined breaking point in the suspension can help control or limit damage to the CPM by determining the point of failure at a specific location on the suspension through design or material selection. In embodiments, the mounting frame has at least one guide for guiding the wireless charging module past the battery in the event of a failure of the at least one suspension and movement of the wireless charging module relative to the battery (5) in the direction of the battery (5). The at least one guide can, in particular, be an inclined edge. The wireless charging module can, in particular, be guided past the battery by passing underneath it.

[0018] By providing such guidance devices, it can be ensured that the wireless charging module does not strike and damage the battery of the electric vehicle in the event of a collision or accident.

[0019] In certain embodiments, at least one suspension point has the form of an arm projecting from the frame. Such a design offers advantages in terms of weight and is particularly easy to adapt to vehicle frames from different platforms or manufacturers, or to vehicle frames with different technical specifications, since only the design of the arms needs to be adapted to the corresponding mounting points on the vehicle frame. This allows different platforms and manufacturers to use the same wireless charging module, which has a positive impact on costs.

[0020] In certain embodiments, the mounting frame, and in particular at least one of the suspensions, has detachable sections for subtractive modification of the mounting frame. Such a design allows adaptation to a multiple vehicle frames from different vehicle platforms or manufacturers, starting from a single mounting frame mold. This makes the manufacturing of the mounting frame more efficient, since, for example, only one injection mold is required to produce an initial mounting frame mold, from which a multiple different mounting frame molds can subsequently be obtained through subtractive modification.

[0021] In certain embodiments, the frame extends parallel to a plane. In particular, the suspensions also extend parallel to the same plane. In other words, the frame, especially the frame and the suspensions, is essentially plate-shaped. Such a design is particularly space-saving and does not unduly restrict the ground clearance of the electric vehicle.

[0022] In some embodiments, the frame has a structure with stiffening elements. In particular, the suspensions can also have a structure with stiffening elements. These stiffening elements can be, for example, ribs, hexagons, honeycomb structures, or pins.

[0023] In embodiments, the frame has at least one fastening element for attaching the wireless charging module to the frame.

[0024] In this text, devices for connecting the wireless charging module to the frame of the mounting bracket are referred to as "fastening elements." To distinguish these, devices for connecting the mounting bracket to the vehicle frame are referred to as "mounting elements."

[0025] In certain embodiments, the at least one fastening element is designed to create a detachable connection between the frame and the wireless charging module. In particular, the detachable connection can be a screwed, plugged, pinned, clipped, or glued connection. In other embodiments, at least one of the mounting elements or suspensions provides a pivotable suspension of the support frame. This simplifies, for example, access to the wireless charging module.

[0026] In some embodiments, the mounting frame incorporates a recessed arrangement of a wireless charging module mounted within the frame. The recessed arrangement can be such that an upper edge of the frame is essentially flush with a surface of the wireless charging module mounted in the frame, or projects a few millimeters, particularly 1 to 10 millimeters, beyond it.

[0027] In some embodiments, the mounting frame is made of plastic. Alternatively or additionally, in other embodiments, the mounting frame is made of a composite material. The thermoplastics and thermosets commonly used in automotive engineering can be used as the plastic or composite material for the mounting frame; these can optionally be reinforced with fibers such as glass fibers. In particular, the mounting frame can be made of polypropylene, which can optionally be reinforced with glass fibers. Such a mounting frame is lightweight yet robust. Manufacturing the mounting frame from a relatively easily deformable material such as plastic can help to absorb vibrations and keep them away from the wireless charging module.

[0028] If the mounting frame is made of an electrically conductive material, it can serve to shield electromagnetic fields. In some embodiments, the mounting frame, in particular the frame itself, forms or incorporates an electrical shield. This electrical shield serves to shield the magnetic field of the wireless charging module and thus contributes to increasing the electromagnetic compatibility of the wireless charging module. If the electrical shield and the frame are separate components, the connection between the electrical shield and the frame can be bonded, screwed, riveted, or overmolded.

[0029] In embodiments, the mounting frame comprises several sets of mounting elements, each set being designed for mounting on a specific vehicle type, and at least one of the sets of mounting elements having separation marks to indicate separation points for the mounting elements of that set. The separation marks are arranged, in particular, in and / or on the suspensions comprising the respective mounting elements of the set in question. The separation marks may be selected from the group consisting of notches, grooves, embossings, and / or engravings.

[0030] Within the scope of the present invention, a "set of mounting elements" is understood to be a subset of the total set of mounting elements of the mounting frame, which is intended for or used to mount the mounting frame on a specific vehicle type or model. In contrast, the remaining mounting elements, i.e., those not belonging to the relevant set of mounting elements or to this subset, are not suitable, for example due to their position and / or location on the mounting frame, to interact with corresponding fastening points, such as threads or recesses, of the relevant vehicle type or model.

[0031] This problem is further solved by a set of mounting brackets according to one of the embodiments described above. Each set of mounting brackets has differently shaped mounting elements, each designed for mounting on a specific type of vehicle. In some embodiments, the mounting bracket has at least one guide and / or recess for at least one electrical current-carrying conductor. Alternatively or additionally, in other embodiments, the mounting bracket has at least one guide and / or recess for at least one fluid-carrying conductor, in particular for at least one cooling line. The guides and recesses can be selected from cutouts and openings in the mounting bracket, in particular in the frame and / or in at least one stiffening element. This allows the at least one electrical current-carrying conductor and / or the at least one fluid-carrying conductor to be positioned in a space-efficient manner within the mounting bracket.They are housed on the support frame and protected against external influences.

[0032] The invention will now be explained in more detail with reference to preferred embodiments, which are illustrated in the accompanying drawings. These schematically depict:

[0033] Figure 1 shows a schematic representation of a vehicle above a wireless charging station;

[0034] Figure 2 shows a perspective view of a mounting frame for a wireless charging module;

[0035] Figure 3 shows a perspective view of a mounting frame with a wireless charging module mounted in it;

[0036] Figure 4 shows a perspective view of another embodiment of a holding frame with a wireless charging module included therein;

[0037] Figure 5 shows a perspective view of another embodiment of a holding frame with a guide and two sets of mounting elements. The reference numerals used in the drawings and their meanings are summarized in the reference numeral list. Generally, identical parts in the figures are designated with the same reference numerals.

[0038] Figure 1 shows a schematic side view of a vehicle 2 above a wireless charging station 3 (GPM, Ground Pad Module), which is located outside the vehicle 2 and includes a transmitter for transmitting an oscillating magnetic field. A wireless charger 4 (CPM, Car Pad Module) for charging a high-voltage battery 5 of the vehicle 2 is arranged above the wireless charging station 3 and inside the vehicle 2.

[0039] Figure 2 shows a perspective view of a mounting frame 6 designed to hold a wireless charging module 4. For this purpose, the mounting frame 6 has a frame 15 with a receiving area 10 arranged between the walls of the frame 15 for receiving the wireless charging module 4. In the embodiment shown in Figure 2, the frame includes four fastening elements 17 in the form of recesses in the frame 15, which can be connected to complementary fastening elements of the wireless charging module 4, for example by means of screws or pins, in order to detachably connect the frame 15 to the wireless charging module 4. In the embodiment of the mounting frame 6 shown in Figure 2, the frame 15 has a plurality of stiffening elements 9, which are designed as ribs extending between and connecting an inner wall and / or an outer wall of the frame 15.The inner wall of the frame 15, as seen in the mounting position of the wireless charging module 4 in the support frame 6, is the surface of the support frame 15 facing the wireless charging module 4. The surface of the frame 15 further away from the wireless charging module 4 forms the outer wall of the frame 15. The support frame 6 also has mounting elements 7 for mounting the support frame 6 to a vehicle, with the embodiment shown in Figure 2 having a total of four mounting elements 7, each arranged at the end of a suspension 8. The suspensions 8 are each designed in the form of an arm projecting from the frame 15 and, like the frame 15 itself, have a plurality of stiffening elements 9 in the form of stiffening ribs. The frame 15 and the suspensions 8 extend parallel to a plane.In the embodiment shown in Figure 2, the support frame 6 further comprises an electrical shield 11, which is attached to the frame 15.

[0040] Figure 3 shows a perspective view of a mounting frame 6 comprising a frame 15, mounting elements 7, suspensions 8, stiffening elements 9, and an electrical shield 11, with the wireless charging module 4 being received in the receiving area arranged between the inner walls of the frame 15. As can be seen from Figure 3, the mounting frame 6 provides a recessed arrangement of the wireless charging module 4 mounted in the mounting frame 6, in which an upper edge of the frame 15 is substantially flush with a surface of the wireless charging module 4 mounted in the frame 15.

[0041] Figure 4 shows a perspective view of another embodiment of a mounting frame 6 with a wireless charging module 4 mounted therein. In addition to the elements already described with reference numerals 7, 9, and 11 in relation to Figures 2 and 3, the suspensions 8 projecting from the frame 15 and designed as arms in the embodiment of the mounting frame 6 shown in Figure 4 each have a predetermined breaking point 12. Furthermore, the mounting elements 7 each have an element 13 for absorbing energy from a relative movement between the vehicle and the mounting frame 6. The elements 13 are designed as rubber buffers, which in the illustrated embodiment are at least partially arranged in the respective mounting elements 7, with one of the elements 13 being shown perpendicularly lifted from the corresponding mounting element 7 for better visibility, as indicated by the dashed line in Figure 4.Thus, the rubber buffers can dampen movements or vibrations both in the plane in which the mounting frame 6 essentially extends and perpendicular to it. However, it is also conceivable that the rubber buffers are essentially completely inserted or pressed into the respective mounting elements, or that they are arranged between the mounting frame and the vehicle frame, resting against the mounting elements.

[0042] Figure 5 shows a perspective view of another embodiment of a mounting frame 6 with a frame 15, which has a receiving area 10 arranged between the walls of the frame 15 for receiving a wireless charging module (not shown in Figure 5). In the embodiment shown in Figure 5, the mounting frame 6 has four suspensions 8, each with a mounting element 7, 7', wherein the four mounting elements can be conceptually divided into two sets of mounting elements, each with two mounting elements. Thus, the mounting frame 6 shown in Figure 5 has a first set of two mounting elements 7 and a second set of two mounting elements 7', wherein each of the four suspensions 8 comprises one of the mounting elements 7, 7' of the first or second set of mounting elements.In principle, it is also conceivable that one or more suspensions 8 of the mounting frame 6 have more than one mounting element, for example, two mounting elements 7 7' of different sets of mounting elements for mounting on at least two different vehicle types. In the embodiment shown, the second set of mounting elements has separation marks 14 to indicate separation points for the mounting elements 7' of the second set of mounting elements, the separation marks 14 being arranged on the suspensions 8 that hold the mounting elements 7' of the second set of mounting elements. The separation marks 14 indicate the positions at which the mounting frame 6 should preferably or may be detached from the mounting elements 7' of the second set of mounting elements – for example, to remove superfluous suspensions for weight reduction or space reasons.This is to ensure, for example, the structural stability of the remaining support frame 6. In the embodiment shown in Figure 5, the separation marks 14 are designed in the form of V-shaped notches in the suspensions 8. These facilitate the application of a suitable separation tool, for example a saw, to remove the respective suspensions or mounting elements from the support frame. The embodiment shown in Figure 5 also includes a guide element 16, which is wedge-shaped or has a beveled edge.The guide element 16 is arranged on a side of the mounting frame 6 facing away from the vehicle's main direction of travel, i.e., towards the rear of the vehicle, and is designed to guide the wireless charging module downwards and under the battery in the event of a failure of the suspensions 8 and a movement of the mounting frame 6 relative to and in the direction of the battery, thus preventing the mounting frame 6 from impacting the battery. The guide element 16 can be formed as an integral part of the frame 15, i.e., as a single piece, or it can be attached to the frame 15 as a separate element.

[0043] REFERENCE MARK LIST

[0044] 2 vehicles

[0045] 3 charging stations

[0046] 4 wireless chargers

[0047] 5 batteries

[0048] 6 support frame

[0049] 7 Mounting element

[0050] 8 Suspension

[0051] 9 stiffening element

[0052] 10 Recording area

[0053] 11 electrical shielding

[0054] 12 Breakaway point in suspension

[0055] 13 Element for absorbing energy from a relative motion between the vehicle and the support frame

[0056] 14 Separation mark in suspension

[0057] 15 frames

[0058] 16 Management tools

[0059] 17 Fastening element

Claims

PATENT CLAIMS 1. Mounting frame (6) for receiving a wireless charging module for charging a battery (5) of a vehicle (2) and / or for supplying power to a consumer of the vehicle (2) and / or for supplying energy from the battery (5) of the vehicle (2) and / or for supplying energy from a power source of the vehicle (2), wherein the mounting frame (6) has a frame (15) for receiving a wireless charging module (4) and mounting elements (7) for mounting the mounting frame (6) on the vehicle (2).

2. Mounting frame (6) according to claim 1, wherein the mounting elements (7) are designed to create a detachable connection of the mounting frame (6) to the vehicle (2), in particular a connection selected from the group consisting of screwed, plugged, pinned, clipped and glued connections.

3. Mounting frame (6) according to one of the preceding claims, wherein one or more of the mounting elements (7) each have a suspension (8) and are flexibly connected to the frame (15) by means of the suspension (8), in particular elastically connected.

4. Mounting frame (6) according to one of the preceding claims, wherein at least one mounting element (7) has an element (13) for absorbing energy from a relative movement between the vehicle (2) and the mounting frame (6).

5. Holding frame (6) according to claim 4, wherein the element (13) comprises or consists of an elastomer.

6. Holding frame (6) according to any one of claims 3 to 5, wherein at least one suspension (8) has a predetermined breaking point (12).

7. Holding frame (6) according to claim 6, comprising at least one guide means (16), in particular an inclined edge, for guiding the wireless charging module (4) past, in particular under, the battery (5) in the event of a breakage of the at least one suspension (8) and a movement of the wireless charging module (4) relative to the battery (5) in the direction of the battery (5).

8. Holding frame (6) according to one of claims 3 to 7, wherein at least one suspension (8) has the form of an arm extending from the frame (15).

9. Holding frame (6) according to one of the preceding claims, wherein the frame (15) extends parallel to a plane, in particular wherein the suspensions (8) also extend parallel to the same plane.

10. Support frame (6) according to one of the preceding claims, wherein the frame (15) has a structure with stiffening elements (9), in particular wherein the suspensions (8) also have a structure with stiffening elements (9).

11. Support frame (6) according to one of the preceding claims, wherein at least one of the mounting elements (7) or the suspensions (8) provides a pivotable suspension of the support frame (6).

12. Mounting frame (6) according to one of the preceding claims, wherein the mounting frame (6) implements a recessed arrangement of a wireless charging module (4) mounted in the mounting frame (6).

13. Mounting frame (6) according to one of the preceding claims, forming or comprising an electrical shield.

14. Mounting frame (6) according to one of the preceding claims, comprising several sets of mounting elements (7, 7'), wherein one set of mounting elements (7, 7') is each provided for mounting on a specific vehicle type, and wherein at least one of the sets of mounting elements (7, 7') has separation marks (14) for indicating separation points for the mounting elements (7, 7') of this set.

15. Set of mounting frames (6) according to one of the preceding claims, each comprising differently shaped mounting elements (7) which are each intended for mounting on a specific type of vehicle.

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