Device having a winding configuration and system, especially charging station, for the non-contact transmission of energy to an electric-powered vehicle, having a winding configuration

• US 9,862,282 B2
• Filed: 01/24/2014
• Issued: 01/09/2018
• Est. Priority Date: 02/11/2013
• Status: Active Grant

• Current Assignee: Sew-Eurodrive GmbH & Company KG (BV Beteiligung GmbH & Company KG)
• Original Assignee: Sew-Eurodrive GmbH & Company KG (BV Beteiligung GmbH & Company KG)
• Inventors: Bser, Andreas, Krempel, Thomas, Schmidt, Josef, Schroeder, Detlev
• Primary Examiner(s): Berhanu, Samuel
• Assistant Examiner(s): Kebede, Tessema
• Application Number:
  US14/766,899
• Publication Number:
  US 20150367739A1
• Time in Patent Office: 1,446 Days
• Field of Search: 320108, 307104, 336 92, 336199, 336208
• CPC Class Codes: B60L 53/12 Inductive energy transfer
• CPC Class Codes: B60L 53/124 Detection or removal of foreign bodies
• 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 27/363 made of electrically conductive material
• 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 device having a winding configuration, especially a layer-type device having a winding configuration, the winding configuration being accommodated in a winding carrier, the winding carrier being situated between a cover part, particularly by which the winding carrier is covered, and a ferrite layer that has openings, especially gaps, the ferrite layer being mounted on a support that is situated on a base part, support domes being provided, especially being integrally molded and/or shaped, on the base part, which protrude through the openings in the ferrite layer and contact and/or support the winding carrier and/or the cover part.

Claims

1. A device, comprising:

a cover part;

a winding carrier;

a winding configuration accommodated in the winding carrier;

a ferrite layer including openings;

a support;

a base part; and

support domes formed in one piece on the base part, wherein;

the support domes protrude through the openings in the ferrite layer and support at least one of the winding carrier and the cover part,

the winding carrier is disposed between the cover part and the ferrite layer, and

the ferrite layer is mounted on the support that is situated on the base part.

2. The device as recited in claim 1, wherein:

the device is a primary-winding configuration,

the support is a support layer,

the openings are gaps, and

the winding carrier is disposed between the cover part and the ferrite layer by that part of the cover part by which the winding carrier is covered,

the support domes are one of integrally molded and shaped.

3. The device as recited in claim 1, wherein the cover part, the winding carrier, the support, and the base part are made of electrically insulating material.

4. The device as recited in claim 1, wherein at least one of:

the base part is able to be placed on a floor and has a wall thickness which increases within a mounting surface on the floor from an outside toward a middle of the mounting surface,

the base part resting on a level floor at least one of is mound-like and has an arched structure, and

the base part has a shape of a truncated pyramid.

5. The device as recited in claim 4, wherein at least one of:

the floor is a level, horizontally extending floor area,

the wall thickness includes one of a vertical thickness and a vertical height,

the base part has an arched shape and water is able to drain off toward the outside, and

a maximum of the arched shape, corresponding to a maximum vertical height above the floor, is centrally located in the base part.

6. The device as recited in claim 1, wherein at least one of:

the cover part is screw-connected with the aid of screw anchors joined to the floor with at least one of a form-locking and force-locking to the floor on which the base part rests,

the cover part is joined imperviously to the base part by pressing an edge section, corresponding to a collar edge, of the cover part onto the base part, including by pressing on an area going around at an outer edge of the base part, and deforming the base part, and

a deformation area of the base part going around at the outer edge of the base part is pressed against the floor by at least one of the screw anchors and a weight force of the base part.

7. The device as recited in claim 1, wherein the winding wire of the winding configuration is joined to the winding carrier by being clipped into corresponding depressions in the winding carrier.

8. The device as recited in claim 1, wherein:

the base part has a centrally located opening in which an electronic component is placed,

winding-wire ends of the winding configuration are connected electrically to connection devices of the electronic component, and

the opening is through-going at least one of parallel to an extension direction of the support domes and vertically to the extension direction.

9. The device as recited in claim 1, wherein:

the openings and the support domes are disposed in an evenly-spaced, planar grid pattern,

the grid pattern is formed of mutually parallel rows set apart evenly from each other,

a spacing within the respective row being uniform,

a distance to the next-adjacent opening in the row corresponding in each case to a grid constant,

rows next-adjacent to each other in each instance having an offset, in an extension direction of the row, of one-half grid constant relative to each other, and

the openings and the support domes are rectangular.

10. The device as recited in claim 1, wherein:

the winding configuration has cross-overs of winding wires that are at least one of implemented and disposed in respective depressions in the winding carrier, and

a vertical level of the depressions rises monotonically from an outer edge of the winding carrier toward a center, so that water penetrating into the device is able to drain off from an inner area toward the outer edge.

11. The device as recited in claim 1, wherein:

the ferrite layer is constructed essentially of homogeneous, cuboidal ferrite plates,

the ferrite plates are disposed in rows that are parallel to each other, with the ferrite plates in rows directly adjacent to each other having an offset,

at least two ferrite plates are situated between each two gaps for a passage of the support domes, and

shorter ferrite plates are located at an end of the row in comparison to the homogeneous ferrite plates.

12. The device as recited in claim 1, wherein the winding carrier and the base part are realized in one piece.

13. The device as recited in claim 1, wherein:

the winding configuration has part-windings,

one turn of a second part-winding is assignable to each turn of a first part-winding in such a way that between each turn of the first part-winding and a turn of the first part-winding following it, an intermediate area and an area difference are enclosed which is equal to the intermediate area enclosed between the two respective assigned turns of the second part-winding,

the area enclosed by the turn of the first part-winding in each instance being equal to the area enclosed by the respective assigned turn of the second part-winding, and

each turn of the first part-winding has a number of cross-overs with the assigned turn of the second part-winding.

14. The device as recited in claim 13, wherein:

the intermediate area has two portions, a first portion being located on longitudinal sides, and another portion on transverse sides of the respective turn,

given a rectangular implementation of each turn, the area difference is split up uniformly in the transverse direction and uniformly in the longitudinal direction, and

a ratio of the first and the other portions correspond to a ratio of length to width of a rectangle.

15. The device as recited in claim 1, wherein:

the winding configuration has part-windings,

one turn of a second part-winding is assigned to each turn of a first part-winding,

each turn of the first part-winding has a number of cross-overs with the assigned turn of the second part-winding, and

an area value of an area wrapped around in each case by the turn of the first part-winding is equal to an area value of an area wrapped around by the respective assigned turn of the second part-winding.

16. The device as recited in claim 15, wherein at least one of:

the first part-winding and the second part-winding are placed in such a way that, by an imaginary rotation through 180°

, the first part-winding is transferable into the second part-winding,

the first part-winding and the second part-winding are placed in such a way that, by rotation through 180°

, the first part-winding is able to be made congruent with the second part-winding,

a number of cross-overs is even,

prior to a cross-over, the winding wire of the specific turn of the first part-winding runs inside of, and after the cross-over, outside of the respective assigned turn of the second part-winding

prior to a cross-over, the winding wire of the specific turn of the first part-winding runs outside of, and after the cross-over, inside of the respective assigned turn of the second part-winding,

the cross-overs are set apart from each other at regular intervals in the direction of turn of a respective turn of at least one of the first part-winding and the second part-winding,

a distance in at least one of a longitudinal direction and a transverse direction of the winding configuration, between one specific turn of the first part-winding and the respective assigned turn of the second part-winding is one of constant and increases monotonically from an outside toward a center,

the part-windings are connected electrically in parallel to each other,

the part-windings are each flat windings, and are windings disposed in a single area, the flat winding in each instance being disposed within a winding area, the winding area running especially in curved fashion,

with the exception of at least one of the regions of the cross-over and the regions where the winding-wire end areas are brought out, the part-windings are flat windings,

litz wire is used as winding wire, the litz wire taking the form of a bundle of individual wires electrically insulated from each other, and

the litz wire is round litz wire, the bundle having essentially a round cross-section.

17. A system for a non-contact transmission of energy to an electric-powered vehicle, comprising:

a device that includes;

a cover part,

a winding carrier,

a winding configuration accommodated in the winding carrier,

a ferrite layer including openings,

a support,

a base part, and

support domes formed in one piece on the base part, wherein;

the support domes protrude through the openings in the ferrite layer and support at least one of the winding carrier and the cover part,

the winding carrier is disposed between the cover part and the ferrite layer, and

the ferrite layer is mounted on the support that is situated on the base part;

an alternating-current source; and

the vehicle, wherein;

an alternating current from the alternating-current source is injectable into the winding configuration, and

the vehicle on a bottom side includes a secondary winding that is able to be coupled inductively to the winding configuration.

18. The system as recited in claim 17, wherein the system is a charging station.

19. The system as recited in claim 17, wherein the winding configuration includes part-windings that are connected in parallel to each other.