Coil unit for a transmission arrangement for inductive transmission of energy

• US 10,290,420 B2
• Filed: 12/15/2015
• Issued: 05/14/2019
• Est. Priority Date: 12/16/2014
• Status: Active Grant

• Current Assignee: Valeo Siemens Eautomotive Germany GmbH (Valeo SE)
• Original Assignee: Siemens AG
• Inventors: Berg, Wilhelm, Biehringer, Hans, Maisel, Peter, Saliternig, Martin
• Primary Examiner(s): Dunn, Drew A
• Assistant Examiner(s): Thapa, Sailesh
• Application Number:
  US14/969,875
• Publication Number:
  US 20160172105A1
• Time in Patent Office: 1,246 Days
• Field of Search: 320108
• CPC Class Codes: B60L 53/124 Detection or removal of foreign bodies
• CPC Class Codes: B60L 53/126 Methods for pairing a vehicle and a charging station, e.g. establishing a one-to-one relation between a wireless power transmitter and a wireless power receiver
• CPC Class Codes: H01F 27/02 Casings
• CPC Class Codes: H01F 27/36 Electric or magnetic shields or screens movable for varying inductance H01F21/10
• CPC Class Codes: H01F 38/14 Inductive couplings for wireless supply or distribution of electric power using inductive coupling H02J50/10
• CPC Class Codes: Y02T 10/70 Energy storage systems for electromobility, e.g. batteries
• CPC Class Codes: Y02T 10/7072 Electromobility specific charging systems or methods for batteries, ultracapacitors, supercapacitors or double-layer capacitors
• CPC Class Codes: Y02T 90/12 Electric charging stations
• CPC Class Codes: Y02T 90/14 Plug-in electric vehicles

Abstract

A coil unit for inductive transmission of energy includes a coil and a flux management unit to manage a magnetic flux during operation of the coil. The flux management unit is arranged behind the at least one coil, when viewed along a coil axis of the coil, and includes at least two flux management sectors and a channel between the flux management sectors. At least partially accommodating the coil and the flux management unit is a housing. A supporting element is arranged between a housing base and a housing lid and configured such that a projection of the supporting element along the coil axis is congruent with or lies within an extent of the flux management unit. A force acting on the housing lid can be diverted via the supporting element past the at least one coil and the at least two flux management sectors to the housing base.

Claims

1. A coil unit for a transmission arrangement for inductive transmission of energy, comprising:

at least one coil having an electrical conductor;

a flux management unit configured to manage a magnetic flux which occurs during operation of the at least one coil, said flux management unit being arranged in a first plane behind the at least one coil, when viewed along a coil axis of the at least one coil, and including at least two flux management sectors and at least one channel between the at least two flux management sectors;

a housing including a housing base and a housing lid configured for attachment to the housing base, said housing at least partially accommodating the at least one coil and the flux management unit; and

at least one supporting element arranged between the housing base and the housing lid and configured such that a projection of the at least one supporting element along the coil axis is congruent with or lies within an extent of the flux management unit, said at least one supporting element being arranged such that a force acting on the housing lid is divertible via the at least one supporting element past the at least one coil and the at least two flux management sectors to the housing base,

wherein the flux management unit has an inner opening with an inner concave circular surface and an outer periphery with an outer convex circular surface, said supporting element has an inner concave circular surface and an outer convex circular surface, and said supporting element is arranged relative to said flux management unit so that either said outer convex circular surface of the supporting element is in direct contact with said inner concave circular surface of said flux management unit, or said inner concave circular surface of said supporting element is in direct contact with said outer convex circular surface of said flux management unit, or both said outer convex circular surface and said inner concave circular surface of said supporting element are in direct contact with said inner concave circular surface and said outer convex surface of said flux management unit correspondingly over a whole circumference.

2. The coil unit of claim 1 for inductive transmission of energy between a charging station having the coil as a stationary primary coil and an automobile having another said coil as an on-board secondary coil.

3. The coil unit of claim 1, wherein the flux management unit has a continuous central opening along the coil axis, said at least one supporting element including a supporting cylinder having at least one section arranged in the central opening.

4. The coil unit of claim 1, wherein the at least one supporting element includes a supporting cuboid having at least one section arranged in the at least one channel.

5. The coil unit of claim 1, wherein the at least one supporting element includes a supporting plate arranged between the housing base and the flux management unit.

6. The coil unit of claim 1, wherein the at least one supporting element includes at least one supporting cuboid and a supporting plate formed in one piece with the supporting cuboid to realize a unitary structure.

7. The coil unit of claim 3, wherein the at least one supporting element includes at least one supporting cuboid and a supporting plate, at least one of the supporting cuboid and the supporting plate being formed in one piece with the supporting cylinder to realize a unitary structure.

8. The coil unit of claim 1, wherein the at least one supporting element includes at least one supporting cover configured to at least partially accommodate at least one of the at least two flux management sectors.

9. The coil unit of claim 5, wherein the at least one supporting element includes at least one supporting cover configured to at least partially accommodate jointly with the housing base or the supporting plate at least one of the at least two flux management sectors.

10. The coil unit of claim 8, wherein the coil includes at least two turns arranged in a second plane in parallel relationship to the first plane, and further comprising a wound supporting cuboid having at least one section arranged between the two turns and between the at least one supporting cover and the housing lid, said supporting cuboid, when viewed along the coil axis, having a thickness which is greater than a thickness of each of the two turns.

11. The coil unit of claim 1, wherein the at least one supporting element is configured at least partially in one piece with at least one of the housing base and the housing lid.

12. The coil unit of claim 1, wherein the electrical conductor has at least one section arranged in the at least one channel that is arranged between the at least two flux management sectors and extends from an inside of the at least one coil to an outside of the at least one coil.

13. The coil unit of claim 1, further comprising at least one positioning coil having at least one section arranged in the at least one channel.

14. The coil unit of claim 1, wherein the flux management unit includes three or four flux management sectors and two or three or four channels between the at least two flux management sectors.

15. The coil unit as claimed in claim 14, further comprising at least one protective screen configured to at least partially surround the at least one positioning coil at least within the flux management unit.

16. The coil unit as claimed in claim 15, wherein the at least one protective screen surrounds the at least one positioning coil in a form of a U defining a gap which is oriented toward the at least one coil, when viewed in a cross-section through the channel.

17. A charging station for a transmission arrangement for inductive transmission of energy, comprising at least one coil unit including a at least one coil having an electrical conductor, a flux management unit configured to manage a magnetic flux which occurs during operation of the at least one coil, said flux management unit being arranged in a first plane behind the at least one coil, when viewed along a coil axis of the at least one coil, and including at least two flux management sectors and at least one channel between the at least two flux management sectors, a housing including a housing base and a housing lid configured for attachment to the housing base, said housing at least partially accommodating the at least one coil and the flux management unit, and at least one supporting element arranged between the housing base and the housing lid and configured such that a projection of the at least one supporting element along the coil axis is congruent with or lies within an extent of the flux management unit, said at least one supporting element being arranged such that a force acting on the housing lid is divertible via the at least one supporting element past the at least one coil and the at least two flux management sectors to the housing base, said at least one coil of the at least one coil unit being embodied as a stationary primary coil, wherein the flux management unit has an inner opening with an inner concave circular surface and an outer periphery with an outer convex circular surface, said supporting element has an inner concave circular surface and an outer convex circular surface, and said supporting element is arranged relative to said flux management unit so that either said outer convex circular surface of the supporting element is in direct contact with said inner concave circular surface of said flux management unit, or said inner concave circular surface of said supporting element is in direct contact with said outer convex circular surface of said flux management unit, or both said outer convex circular surface and said inner concave circular surface of said supporting element are in direct contact with said inner concave circular surface and said outer convex surface of said flux management unit correspondingly over a whole circumference.

18. An automobile for a transmission arrangement for inductive transmission of energy, comprising at least one coil unit including a at least one coil having an electrical conductor, a flux management unit configured to manage a magnetic flux which occurs during operation of the at least one coil, said flux management unit being arranged in a first plane behind the at least one coil, when viewed along a coil axis of the at least one coil, and including at least two flux management sectors and at least one channel between the at least two flux management sectors, a housing including a housing base and a housing lid configured for attachment to the housing base, said housing at least partially accommodating the at least one coil and the flux management unit, and at least one supporting element arranged between the housing base and the housing lid and configured such that a projection of the at least one supporting element along the coil axis is congruent with or lies within an extent of the flux management unit, said at least one supporting element being arranged such that a force acting on the housing lid is divertible via the at least one supporting element past the at least one coil and the at least two flux management sectors to the housing base, said at least one coil of the at least one coil unit being embodied as an on-board secondary coil, wherein the flux management unit has an inner opening with an inner concave circular surface and an outer periphery with an outer convex circular surface, said supporting element has an inner concave circular surface and an outer convex circular surface, and said supporting element is arranged relative to said flux management unit so that either said outer convex circular surface of the supporting element is in direct contact with said inner concave circular surface of said flux management unit, or said inner concave circular surface of said supporting element is in direct contact with said outer convex circular surface of said flux management unit, or both said outer convex circular surface and said inner concave circular surface of said supporting element are in direct contact with said inner concave circular surface and said outer convex surface of said flux management unit correspondingly over a whole circumference.

19. A transmission arrangement for inductive transmission of energy, comprising:

at least one charging station comprising at least one coil unit including a at least one coil having an electrical conductor, a flux management unit configured to manage a magnetic flux which occurs during operation of the at least one coil, said flux management unit being arranged in a first plane behind the at least one coil, when viewed along a coil axis of the at least one coil, and including at least two flux management sectors and at least one channel between the at least two flux management sectors, a housing including a housing base and a housing lid configured for attachment to the housing base, said housing at least partially accommodating the at least one coil and the flux management unit, and at least one supporting element arranged between the housing base and the housing lid and configured such that a projection of the at least one supporting element along the coil axis is congruent with or lies within an extent of the flux management unit, said at least one supporting element being arranged such that a force acting on the housing lid is divertible via the at least one supporting element past the at least one coil and the at least two flux management sectors to the housing base, said at least one coil of the at least one coil unit being embodied as a stationary primary coil, wherein the flux management unit has an inner opening with an inner concave circular surface and an outer periphery with an outer convex circular surface, said supporting element has an inner concave circular surface and an outer convex circular surface, and said supporting element is arranged relative to said flux management unit so that either said outer convex circular surface of the supporting element is in direct contact with said inner concave circular surface of said flux management unit, or said inner concave circular surface of said supporting element is in direct contact with said outer convex circular surface of said flux management unit, or both said outer convex circular surface and said inner concave circular surface of said supporting element are in direct contact with said inner concave circular surface and said outer convex surface of said flux management unit correspondingly over a whole circumference; and

at least one automobile as set forth in claim 18.