Coil unit and electric vehicle

• US 9,824,805 B2
• Filed: 02/01/2013
• Issued: 11/21/2017
• Est. Priority Date: 04/17/2012
• Status: Active Grant

• Current Assignee: ENRX IPT GmbH
• Original Assignee: Conductix-Wampfler GmbH (Delachaux Group SA)
• Inventors: Wechlin, Mathias, Asselin, Pascal, Green, Andrew
• Primary Examiner(s): Tso, Edward
• Assistant Examiner(s): OMAR, AHMED H
• Application Number:
  US14/395,152
• Publication Number:
  US 20150061593A1
• Time in Patent Office: 1,754 Days
• Field of Search: 320108
• CPC Class Codes: B60L 53/12 Inductive energy transfer
• CPC Class Codes: H01F 3/00 Cores, Yokes, or armatures magnetic materials H01F1/00; permanent magnets H01F7/02
• 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 an electric vehicle for the inductive transfer of electrical energy between the coil unit and a stationary charging station. The coil unit includes at least one coil and a flux guide unit for guiding a magnetic flux occurring during operation of the coil. Also disclosed is an electric vehicle having a coil unit for the inductive transfer of electrical energy between a secondary coil of the coil unit and a primary coil of a charging station. The disclosed coil solves the problem of allowing the safe use of the inductive electrical energy transfer in electric vehicles, in particular motor vehicles, by proposing a coil unit, in which the flux guide unit has material weakenings, and an electric vehicle having such a coil unit.

Claims

1. A device for inductive transfer of electrical energy between an electric vehicle and a charging coil, comprising:

at least one coil; and

a flux guide unit for guidance of a magnetic flux appearing during the operation of the coil, wherein the flux guide unit has material weaknesses configured, completely or partially, as predetermined breaking points, the material weaknesses extending in a plane of the flux guide unit that is parallel to the longitudinal direction of the vehicle and at an inclined angle relative to the plane.

2. The device according to claim 1, wherein the material weaknesses essentially run transverse to the longitudinal direction of the vehicle.

3. The device according to claim 1, wherein the material weaknesses essentially run concentric to a center of the flux guide unit.

4. The device according to claim 1, wherein the material weaknesses essentially run in the direction of the magnetic field lines of the magnetic flux guided in the flux guide unit.

5. The device according to claim 1, wherein the material weaknesses in the flux guide unit are provided grooves.

6. The device according to claim 1, wherein the material weaknesses are provided on different flat sides of the flux guide unit.

7. The device according to claim 1, wherein the material weaknesses are alternatingly provided on the different flat sides of the flux guide unit.

8. The device according to claim 1, wherein the material weaknesses are partial or complete breaks of the flux guide unit.

9. The device according to claim 1, wherein the breaks are, partially or completely, filled with an adhesive and/or bonding material.

10. The device according to claim 9, wherein the adhesive and/or the bonding material has ferromagnetic or ferrimagnetic characteristics.

11. Electric vehicle with a coil unit for inductive transfer of electrical energy between a secondary coil of the coil unit and a primary coil of a charging station, wherein the coil unit is designed in accordance with claim 1.

19. The device of claim 1, a section of the flux guide defined by the material weaknesses on opposite sides of the section, the angles inclined to guide the section in a direction away from a passenger compartment of the electric vehicle when one or more adjacent portions of the flux guide are pushed against the section during an accident of the vehicle.

20. The device of claim 19, further including a sheet positioned adjacent to the section, the sheet sized and configured to resist movement of the section away from the vehicle during the accident of the vehicle.

12. A device for inductive transfer of electrical energy between an electric vehicle and a stationary charging station, comprising:

at least one coil; and

a flux guide unit positioned proximate the coil for guidance of a magnetic flux arising during the operation of the coil, the flux guide unit having a plurality of predetermined material weaknesses as paths extending along the flux guide unit, the paths disposed at an angle with respect to a planar surface of the flux guide unit, each path formed as at least one of a gap or weaker material relative to adjacent material of the flux guide unit, the paths sized and dimensioned to cause the flux guide unit to break free a substantial portion of the flux guide that is bounded by at least one of the weakened paths and to to guide the portion along the angled path to eject the portion away from a passenger compartment of the electric vehicle during an impact accident of the electrical vehicle to thereby reduce movement inertia of the flux guide and to thereby safeguard passengers of the electric vehicle from intrusion of the flux guide unit into the passenger compartment.

13. The device of claim 12, the predetermined material weaknesses extending along a direction transverse to the longitudinal direction of the vehicle as defined when the device is installed in the electric vehicle.

14. The device of claim 12, the material weaknesses in the flux guide unit having the form of grooves formed in the surface of the magnetic flux unit.

15. The device of claim 12, the material weaknesses being provided on upper and lower surfaces of the magnetic flux unit as defined when the magnetic flux unit is installed in the electric vehicle.

16. The device of claim 12, the predetermined material weaknesses extending into at least one of the upper and lower surfaces of the magnetic flux unit as defined when the magnetic flux unit is installed in the electric vehicle, the weaknesses extending into the at least one upper and lower surface at an incline with respect to the respective upper or lower surface.

17. The device of claim 12, the predetermined material weaknesses formed as gaps between portions of the magnetic flux unit, the gaps at least one of partially or completely filled with at least one of an adhesive and bonding material that has at least one of ferromagnetic or ferrimagnetic characteristics.

18. A method of fabricating a flux guide unit for guidance of a magnetic flux during the operation of a coil aboard a moving electric vehicle obtaining power from a stationary power source, the method comprising:

forming a plurality of predetermined material weakness as paths extending along the flux guide unit, each path formed as at least one of a gap or weaker material relative to adjacent material of the flux guide unit, the paths sized and dimensioned and disposed at an angle relative to a longitudinal plane of the flux guide unit surface to cause the flux guide unit to break into portions and to cause at least one of the portions to break free and to be guided by the angled path to be thereby ejected in a direction away from the passenger compartment during an impact accident of the electrical vehicle to thereby reduce movement inertia of the flux guide and avoid intrusion of portions of the flux guide unit into the passenger compartment.