Fixed core inductive charger

• US 5,434,493 A
• Filed: 10/25/1993
• Issued: 07/18/1995
• Est. Priority Date: 10/25/1993
• Status: Expired due to Term

• Current Assignee: GM Global Technology Operations LLC (General Motors Company)
• Original Assignee: Hughes Aircraft Company (Rtx Corporation)
• Inventors: Woody, George R., Tanzer, Herbert J., Hall, John T.
• Primary Examiner(s): KINCAID, KRISTINE LYNN
• Application Number:
  US08/140,954
• Time in Patent Office: 631 Days
• Field of Search: 320/2, 320/21, 336/DIG. 2
• US Class Current: 320/108
• CPC Class Codes: B60L 53/12 Inductive energy transfer
• 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 38/14 Inductive couplings for wireless supply or distribution of electric power using inductive coupling H02J50/10
• CPC Class Codes: H02J 5/00 Circuit arrangements for transfer of electric power between ac networks and dc networks H02J3/36 takes precedence
• CPC Class Codes: H02J 50/10 using inductive coupling
• CPC Class Codes: H02J 7/0042 characterised by the mechanical construction
• 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
• CPC Class Codes: Y10S 336/02 Separable

Abstract

An inductively-coupled transformer charging apparatus comprising a charging port having a nonmoving secondary core and a charging coupler that is insertable therein. The charging coupler comprises a primary winding disposed around a primary core. The charging port comprises a fixed secondary core comprising two secondary core halves and two secondary windings, and includes an opening into which the charging coupler is inserted. Heat transfer media in the charging port remove heat during charging. The opening and coupler are sized such that a gap is provided between the secondary core halves and the coupler to provide for a slip fit therebetween. The close fitting relationship between the coupler and the charge port acts to remove dirt build-up present on the coupler as it is inserted into the charging port. The basic requirements of the present invention are that the secondary core has a fixed, nonmoving configuration, that the coupler be insertable into the secondary core, and that the center magnetic core of the coupler form part of a complete magnetic circuit in conjunction with the secondary core. The advantages of the present invention are simplicity and reliability. The present invention does not require moving parts to open and close the primary core halves. The gap provided between the secondary core halves and the inserted coupler is designed so that the respective cores are separated by a minimum, predefined distance, both of which are important parameters of the electrical design of the charging apparatus. Also, there are fewer problems due to dirt buildup due to the wiping action provided by the charging port when the coupler is inserted therein.

Claims

1. Inductive charging apparatus comprising:

a charge port comprising;

a charge port housing;

an outer heat exchanger disposed adjacent the internal periphery of the charge port housing;

first and second magnetically coupled magnetic core halves with an opening therebetween providing for a predetermined spacing between adjacent surfaces of the magnetic core halves, wherein said core halves are disposed in the charge port housing adjacent the heat exchanger;

first and second secondary windings disposed adjacent the opening formed between the first and second magnetic core halves and disposed in an opening formed in each of the first and second magnetic core halves; and

a charging coupler comprising;

a coupler housing;

a center magnetic core disposed in the coupler housing; and

a primary winding disposed around the center magnetic core;

and wherein the center magnetic core has a dimension such that defines a predetermined, relatively fixed gap between the respective adjacent surfaces of the first and second magnetic core halves and respective outer surface of the center magnetic core when the charging coupler is inserted into the charge port.

2. The apparatus of claim 1 wherein the first and second magnetic core halves comprise portions of an E-shaped core.

3. The apparatus of claim 1 wherein the shape of the center magnetic core is round.

4. The apparatus of claim 1 wherein the shape of the center magnetic core is rectangular.

5. The apparatus of claim 1 wherein the center magnetic core and magnetic core halves are disposed in an EE core configuration.

6. The apparatus of claim 1 Wherein the center magnetic core and magnetic core halves are disposed in an EP core configuration.

7. The apparatus of claim 1 wherein the center magnetic core and magnetic core halves are disposed in an RS core configuration.

8. The apparatus of claim 1 wherein the primary and secondary windings comprise helix-shaped windings.

9. The apparatus of claim 1 wherein the primary and secondary windings comprise multiple layer windings.

10. The apparatus of claim 1 wherein the primary and secondary windings comprise flat spiral windings having a single layer.

11. The apparatus of claim 1 wherein the center magnetic core has a circular shape.

12. The apparatus of claim 1 wherein the center magnetic core has a rectangular shape.

13. Inductive charging apparatus comprising:

a charge port comprising;

a charge port housing;

an outer heat exchanger disposed adjacent the internal periphery of the charge port housing;

first and second magnetically coupled ferrite core halves with an opening therebetween providing for a predetermined spacing between adjacent surfaces of the core halves, wherein said core halves are disposed in the charge port housing adjacent the heat exchanger;

first and second secondary windings disposed adjacent the opening formed between the first and second ferrite core halves and disposed in an opening formed in each of the first and second ferrite core halves; and

first and second inner heat exchangers disposed between the first and second secondary windings and the first and second ferrite core halves;

a charging coupler comprising;

a coupler housing;

a ferrite center core disposed in the coupler housing; and

a primary winding disposed around the ferrite center core;

and wherein the ferrite center core has a dimension such that a predetermined, relatively fixed gap is provided between the respective adjacent surfaces of the first and second ferrite core halves and respective outer surface of the ferrite center core when the charging coupler is inserted into the charge port.

14. The apparatus of claim 13 wherein the first and second magnetic core halves comprise portions of an E-shaped core.

15. The apparatus of claim 13 wherein the shape of the center magnetic core is round.

16. The apparatus of claim 13 wherein the shape of the center magnetic core is rectangular.

17. The apparatus of claim 13 wherein the primary and secondary windings comprise helix-shaped windings.

18. The apparatus of claim 13 wherein the primary and secondary windings comprise multiple layer windings.

19. The apparatus of claim 13 wherein the primary and secondary windings comprise flat spiral windings having a single layer.