Charging Device Having and Method for Producing an Induction Coil

• US 20180134165A1
• Filed: 01/12/2018
• Published: 05/17/2018
• Est. Priority Date: 09/25/2015
• Status: Active Grant

• Current Assignee: Bayerische Motoren Werke AG
• Original Assignee: Bayerische Motoren Werke AG
• Inventors: KEIL, Cornelius Johan Kalle, KRAMMER, Josef, MUELLER, Tobias, EGGERS, Hartmut, OPL, Stefan
• Granted Patent: US 11,001,156 B2
• Time in Patent Office: Days
• CPC Class Codes: B60L 53/124 Detection or removal of foreign bodies
• CPC Class Codes: B60L 53/38 specially adapted for charging by inductive energy transfer
• CPC Class Codes: H01F 27/2823 Wires H01F27/2866 takes precedence
• CPC Class Codes: H01F 41/04 for manufacturing coils coils for transformer or inductances H01F27/28
• CPC Class Codes: H02J 50/60 responsive to the presence of foreign objects, e.g. detection of living beings
• 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 method is provided for producing an induction coil, in particular for a charging device for the cableless charging of an electrical energy storage device of an electrically driven motor vehicle. At least one coil wire is placed on a carrier fabric in a conductor loop-type coil pattern. The coil wire is stitched to the carrier fabric via at least one stitching wire.

Claims

1. A method for producing an induction coil for a charging device for wirelessly charging an electrical energy accumulator of an electrically drivable motor vehicle, the method comprising the acts of:

placing at least one coil wire on a carrier cross-laid structure in a conductor-loop coil profile; and

fastening, by stitching, at least one coil wire on the carrier cross-laid structure via at least one stitching wire.

2. The method as claimed in claim 1, wherein

the coil wire is arranged on the carrier cross-laid structure in a helical coil profile.

3. The method as claimed in claim 1, wherein

the coil wire is arranged in paths of the coil profile that run in parallel.

4. The method as claimed in claim 3, wherein

in the case of fastening by stitching, a plurality of neighboring paths of the coil wire are spanned by one stitching thread.

5. The method as claimed in claim 1, wherein

the coil wire is formed by a number of individual wires,

the individual wires are arranged in parallel paths in a permuting manner such that each individual wire in the coil profile assumes each position of the path at least once.

6. The method as claimed in claim 1, further comprising the act of:

stitching a sensor wire of a sensor coil to the carrier cross-laid structure.

7. The method as claimed in claim 6, wherein

the sensor wire is disposed so as to be centric within the coil profile.

8. The method as claimed in claim 1, wherein

the stitching wire is produced from an electrically conductive material.

9. A charging device for wirelessly charging an electrical energy accumulator of an electrically drivable motor vehicle, the charging device comprising:

a stationary primary coil;

a vehicle-side secondary coil, wherein the primary coil is capable of being coupled inductively to the secondary coil for charging of the electrical energy accumulator;

a sensor coil assembly that positions the secondary coil in a region of the primary coil, wherein

at least one of the secondary coil and the primary coil comprise at least one coil wire arranged on a carrier cross-laid structure in a conductor-loop coil profile and fastened, via stitching using a stitching wire, on the carrier cross-laid structure.

10. The charging device as claimed in claim 9, wherein

the sensor coil assembly comprises an array of neighboring sensor coils.