Coil unit of a device for inductive transmission of electrical power

• US 10,369,892 B2
• Filed: 02/21/2017
• Issued: 08/06/2019
• Est. Priority Date: 02/22/2016
• Status: Active Grant

• Current Assignee: ENRX IPT GmbH
• Original Assignee: Ipt Technology Gmbh
• Inventors: Cordes, Felix, Endler, Niklas
• Primary Examiner(s): Grant, Robert
• Assistant Examiner(s): McDaniel, Tynese V
• Application Number:
  US15/437,773
• Publication Number:
  US 20170240057A1
• Time in Patent Office: 896 Days
• Field of Search: None
• CPC Class Codes: B60L 53/12 Inductive energy transfer
• CPC Class Codes: B60L 53/30 Constructional details of charging stations
• CPC Class Codes: B60L 53/34 Plug-like or socket-like devices specially adapted for contactless inductive charging of electric vehicles positioning means for charging devices using inductive energy transfer B60L53/38
• CPC Class Codes: H01F 27/02 Casings
• CPC Class Codes: H01F 38/14 Inductive couplings for wireless supply or distribution of electric power using inductive coupling H02J50/10
• CPC Class Codes: H02J 50/10 using inductive coupling
• CPC Class Codes: H02J 50/90 involving detection or optimisation of position, e.g. alignment
• 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

In a coil unit of a device for inductive transmission of electrical power with a cover, a base and a coil arranged between the cover and base. During operation of the device, the cover faces another coil unit and the base faces away from it. At least one support element, which mechanically supports the cover on the base, is arranged between the cover and the base. At least one cavity is formed between the cover and the support element by protrusions on the cover and/or on the support element, whereby the cover lies on the support element, and/or at least one cavity is formed between the base and the support element by protrusions on the support element and/or on the base, whereby the support element lies on the base. Sensors or elements for magnetic flux guidance can be arranged protected from mechanical load in such a cavity.

Claims

1. A coil unit of a device for inductive transmission of electrical power, said coil unit comprising:

a cover;

a base;

a coil arranged between the cover and the base, during operation of the device the cover facing another coil unit and the base facing away from the other coil unit;

at least one support element arranged between the cover and the base, the at least one support element mechanically supporting the cover on the base;

at least one cavity formed between the cover and the support element by first protrusions on at least one of the cover and the support element, the cover mechanically supported on the support element via the first protrusions;

at least one other cavity formed between the base and the support element by second protrusions on at least one of the support element and the base, the support element mechanically supported on the base via the second protrusions; and

proximity sensors to detect an object lying on the cover arranged in the at least one cavity formed between the cover and the support element,

wherein the proximity sensors are inductive sensors in the form of measuring coils, which are distributed in a regular arrangement laterally over the coil unit; and

wherein two layers of measuring coils are arranged one above the other, all of the measuring coils of one layer arranged between first protrusions, all of the measuring coils of the other layer are arranged enclosing first protrusions, and the two layers are laterally offset relative to each other so that the measuring coils of one layer cover the intermediate spaces not covered by the measuring coils of the other layer.

2. The coil unit according to claim 1, wherein the coil unit is the primary coil unit of a charging station for an electric vehicle, the coil is the primary coil of the charging station, and the other coil unit is the secondary coil unit of the electric vehicle.

3. The coil unit according to claim 1, wherein the first and second protrusions are formed in one part with the support element.

4. The coil unit according to claim 1, wherein the first and second protrusions each include a number of individual protrusions separate from each other.

5. The coil unit according to claim 1,

wherein the first protrusions extend symmetrically about an axis perpendicular to the surface of the cover and/or the support element,

the second protrusions extend symmetrically about an axis perpendicular to the surface of the support element and/or the base, and

the first protrusions have an end surface lying parallel to the cross-sectional surface of the coil unit as well as a rounded cross-sectional shape without corners.

6. The coil unit according to claim 1, wherein a second protrusion is provided between the support element and the base for each first protrusion between the cover and the support element at the same lateral position.

7. The coil unit according to claim 1, wherein the first protrusions are formed on the support element, and the second protrusions are formed on the support element.

8. The coil unit according to claim 1,

wherein

the measuring coils are mechanically fixed by first protrusions in the lateral direction.

9. The coil unit according to claim 1, wherein flux guidance elements are arranged in the at least one other cavity formed between the base and the support element, the flux guidance elements being in the form of plates of a material with high magnetic permeability.

10. The coil unit according to claim 1,

wherein grooves, starting from the at least one other cavity formed between the support element and the base, are formed in the support element, and

windings of the coil provided for power transmission are positioned in the grooves.

11. The coil unit according to claim 1, wherein the at least one cavity formed between the cover and the support element is closed off outwardly by at least one peripheral ridge on the edge of the support element and/or on the edge of the cover and

the at least one other cavity formed between the support element and the base is closed off outwardly by at least one continuous ridge on the edge of the support element and/or on the edge of the base.

12. The coil unit according to claim 1, wherein the support element is formed in one piece and includes a fiber-reinforced thermosetting plastic, the cover includes a fiber-reinforced thermosetting plastic, and the base is formed of metal.

13. The coil unit according to claim 1, wherein upper end surfaces of the first protrusions form first support surfaces that mechanically support the cover on the support element, and lower end surfaces of the second protrusions form second support surfaces that mechanically support the support element on the base.

14. The coil unit according to claim 6, wherein a force exerted on the cover is taken up by the first protrusions, passed directly through the support element, and transferred through the second protrusions to the base.

15. The coil unit according to claim 1,

wherein flux guidance elements are arranged in the at least one other cavity formed between the base and the support element, the flux guidance elements being in the form of plates of a material with high magnetic permeability,

the proximity sensors arranged in the at least one cavity are protected from mechanical load by the first protrusions, and

the flux guidance elements arranged in the at least one other cavity are protected from mechanical load by the second protrusions.