EP3003773A1 - Transfer element - Google Patents

Abstract

A transfer element (1, 1a), preferably as a secondary part of an inductive charging system for electric vehicles, comprises a secondary coil (2) and an electronic system (4) integrated into the housing (3). The housing (3) comprises a pot-shaped section (6) of a magnetically shielding material, which has an open side (7), the secondary coil (2) surrounding the section (6) from the outside.

Description

 transducer element

This application claims the benefit of European Application No. EP13169731 .0 filed on May 29, 2013, the entirety of which is expressly incorporated herein by reference in its entirety and in any part whatsoever, for all purposes and purposes with identical complete absorption in the subject

Registration.

The invention relates to a transformer element for a system for contactless energy transmission between at least one primary part and at least one secondary part, according to the preamble of claim 1, as well as a system for contactless energy transmission and a vehicle with such a system.

WO 2013/017200 A1 discloses an electronic device,

in particular a transformer head for supplying the drive of an at least partially electrically operated vehicle based on inductive energy transmission. This device has a housing with a secondary winding and an integrated rectifier inside. The secondary winding feeds the rectifier, which is electrically connected to the secondary winding and supplied from the secondary winding. EP 2572427 A2 also shows an arrangement in which a secondary winding arrangement is electrically connected to a rectifier, which is thus fed by the secondary winding arrangement.

Both EP 2515314 A1 and WO 2012/144640 A1 disclose simple bush-like or pot-like structures whose opening faces away from the vehicle (floor) and in the interior of which the secondary coils are completely accommodated. Electronic components, however, are not provided in these pot-like structures, because of the strong magnetic alternating fields immediately failures or the destruction of these

sensitive components would take place. These documents show the desire for integration of electrical and / or electronic components in the device housing, in which the secondary coil is provided. However, this is only possible to a limited extent, since these housings are naturally exposed to the strong magnetic fields for energy transfer. The integration of sensitive electronic components, as used for the operation and control of

Secondary side are necessary, so it is difficult or these components are then very prone to failure.

Object of the present invention is thus to provide a transformer element for a system for contactless energy transfer, which allows the use of strong alternating magnetic fields to achieve the best possible ratio of transmitted energy to transmission time and yet a high degree of integration of electrical and / or electronic Components in the housing of the transformer element allows.

The object is solved by the features of independent claim 1. Advantageous developments are set forth in the figures and in the dependent claims.

As in the case of the known devices, the transformer element comprises at least one coil and electronics and a connection for a power supply and / or a battery to be charged, wherein at least one coil and the electronics are accommodated in a common housing.

According to the invention, however, the housing also comprises or includes a cup-shaped section of magnetically shielding material, preferably of ferrite, with at least one open side and at least one secondary coil surrounding the pot-like section on the latter

Outside. Deviating from the known solutions surrounds the

Secondary coil the pot-like section on the outside and the pot itself is exactly opposite to the known versions oriented. By this construction and their spatial orientation can shield the sensitive electrical and electronic

Components can be achieved without hindering the transfer of energy too much, since the magnetic field along the cup-like portion on the inside around and preferably completely through the surrounding the pot coil of the Übertragerelementes is passed.

Advantageously, the open side of the housing is at least partially provided with a cover of magnetically shielding material. Such a construction provides further improved shielding

sensitive components against strong magnetic fields, while the

Penetration of the coil for energy transfer is not affected. The cover is preferably made of aluminum.

According to a further exemplary embodiment of the invention, between the cover and the bottom and / or the side walls of the pot-like section at least part of the electronics are surrounded by wall elements of magnetically shielding material so as to obtain an all-round shielding of the electronics of the transformer element.

In order to impede the energy transfer as little as possible, an advantageous embodiment of the invention is characterized in that a magnetically permeable region remains between the cover and the open side of the pot-like portion of the housing, preferably at least one coil in and preferably below this permeable region is arranged.

If advantageously at least one heat-conducting element,

Preferably, at least one copper plate, the housing connects with at least one of the components arranged therein, despite good

Magnetic shielding the dissipation of heat from the protected components are ensured to the outside. In a further inventive embodiment of the transformer element, the interior of the housing has a

Potting compound, which preferably completely surrounds the components contained therein. Thus, the mechanical strength and the

Resistance to mechanical stresses are significantly improved.

Preferably, the electronics of the Übertragerelementes a

Clamp on, so that overvoltage protection for the

To ensure rapid shutdown of the current flow on the secondary side in an emergency. Preferably, this is also called Crowbar

Protection circuit of a rectifier circuit of the secondary part

downstream and preferably upstream of an output filter.

Preferably, a transformer element according to at least one of the preceding paragraphs is used as a secondary part for a system

contactless energy transfer between at least one primary part and at least one secondary part application, in particular as mounted on a vehicle secondary part for supplying a

Energy storage system of the vehicle.

In a system for contactless energy transmission between at least one primary part and a secondary part, preferably a system for contactless charging of at least partially electrically operated

Vehicles, is provided according to the invention that the secondary part at least one transformer element according to at least one of

previous paragraphs.

The solution of the problem initially posed is also in a vehicle with at least partially electric drive, preferably with a

Traction battery for feeding the electric drive with electrical energy, given that has the secondary part of a system for contactless energy transmission, if the secondary part at least one Having transmitter element according to at least one of the preceding paragraphs.

Further advantages, features and details of the invention will become apparent from the following description, with reference to the

Drawings embodiments of the invention are described. The features mentioned in the claims and in the description may each be essential to the invention individually or in any desired combination.

The list of reference numerals is part of the disclosure. The figures are described coherently and comprehensively. The same reference symbols denote the same components, reference symbols with different indices indicate functionally identical or similar components.

It shows:

Fig. 1 shows a first embodiment of an inventive

 Übertragerelementes in perspective, partially sectioned view in a schematic representation,

Fig. 2a shows another embodiment of an inventive

 Übertragerelementes, in a sectional view parallel to the secondary coil,

Fig. 2b shows the embodiment of Fig. 2a in a longitudinal section perpendicular to the view of Fig. 2a, and

Fig. 3 shows an exemplary electrical circuit diagram of a

 inventive transformer element.

Fig. 1 shows a first embodiment of a transformer element 1, preferably as a secondary part of an inductive charging system for

Electric vehicles or for at least partially electrically powered vehicles. The magnetic alternating field generated by a primary part penetrates at least one secondary coil 2 and is then converted into a charging current for in particular the traction battery 5 (see FIG. 3) of the vehicle by means of an integrated in the housing 3 of the transformer element 1 electronics 4. The housing 3 of the transformer element 1 can be made of any material, of course, with secondary coil 2 located inside the housing 3, of magnetically non-shielding material, such as plastic.

The housing 3 also includes or includes a cup-shaped portion 6 of magnetically shielding material, preferably ferrite. This section 6 may be formed on the housing 3 itself or be a separately manufactured and connected to the housing 3 component. One side 7 of this section 6 is open and has, when the transmitter element 1 is operated as intended, away from the primary part. Thus, the electronics 4 located in the housing 3 is shielded from most of the magnetic field generated by the primary part. At least one

Secondary coil 2 preferably surrounds the pot-like portion 6 on the outside thereof, wherein the magnetic shielding through the ferrite portion 6 advantageously as a derivative or diversion of the

Magnetic field lines around sensitive components around and through the

Secondary coil 2 acts through.

Advantageously, the open side 7 of the housing 3 or its pot-like portion 6 is at least partially provided with a cover 8 also made of magnetic shielding material such as ferrite. The cover 8 preferably covers a larger area than the portion 6 - seen normal to the direction of the magnetic field lines - and thus surmounted both this section 6 and the secondary coil. 2

At best, the edge of the cover 8 also on the sides of

Secondary coil 2 pulled around, in particular be pulled down when applied, for example, at the bottom of a vehicle, so that through the cover 8, a pot-like portion 6 opposite oriented pot-like structure is formed. This embodiment is preferably provided in the formation of the cover 8 made of ferrite material.

According to another embodiment, additionally or alternatively to the construction explained above, the upper edge of the pot-like section 6 is designed radially outward and the coil at least partly overlapping and projecting (see FIG. 1). It is preferred even and analogous to the cover 8, the upper edge of the cup-like portion 6 the

Secondary coil 2 radially outwardly at least covering, better even this coil 2 radially outstanding and even more preferably pulled down on the radial outer side at least over part of the height of the secondary coil 2, so that the edge of the cup-shaped portion 6 a coil 2 comprehensive annular trough with the opening of the cup-shaped portion 6 opposite orientation forms.

In order to optimize the shielding effect for the electronics 4 of the transformer element 1, between the cover 8 and the bottom 6a and / or the side walls 6b of the pot-like portion 6 at least parts of the electronics 4 with wall elements (not shown) from also magnetically shielding material, preferably Wall elements of ferrite, to be surrounded.

Within the first shield through the cup-shaped portion 6 so that a further shielding is provided by the wall elements for the electronics 4 or other sensitive components. These wall elements in

Interior of the secondary coil 2, typically perpendicular to the bottom 6a of the cup-shaped portion 6 and / or the cover 8, result

together with the cover 8 and the section 6 a kind of magnetic "Faraday cage" around the electronic components 4 around and also act as a conductor for the magnetic field lines around the electronics 4 and through the secondary coil. 2

The secondary coil 2 and possibly also the interior of the housing 3, preferably also the interior of the pot-like portion 6, can be at least partially filled with a potting compound 9. This at least partially surrounds the components contained in the housing 3, preferably the secondary coil 2 and / or the electronics 4 in order to protect them against moisture and / or mechanical stresses, in particular bumps or vibrations during driving of the electric vehicle.

FIGS. 2 a and 2 b show a somewhat different embodiment of a transformer element 1 a according to the invention. Here, the housing 3 is covered by a thin, lightweight plate 8a made of, for example, aluminum and closed to the outside. Inside the housing 3 is again a cup-shaped shield 6 to the electronics 4, preferably made of ferrite, which is open on one side. Over the cover 8,

advantageously made of aluminum, copper or another good

made of thermally conductive material, the heat is dissipated by the electronics 4 in the environment and so the electronics 4 cooled. Such cooling arrangements can be provided in all embodiments according to the invention. The connections 12 for control and sensor lines from and to the electronics 4 as well as the connections 13 for the battery 5 to be charged can be seen in FIGS. 2a and 2b.

In addition to the region of the secondary coil 2, it can also be clearly seen in FIGS. 2 a and 2 b that the interior of the housing 3 can also at least partially be filled with the potting compound 9. These

Potting compound 9 at least partially surrounds the components contained in the housing 3, preferably the secondary coil 2 and / or the electronics 4.

Alternative embodiments may provide housing, which includes the secondary coil 2 in its interior, wherein the secondary coil 2 is covered by a frame and preferably encapsulated. Also, on the interior of the housing facing surface of this frame and preferably also between the components of the electronics 4 thin plates of ferrite or other magnetic

shielding material arranged as a wall and partition elements be. These panels as wall elements can also form the cup-shaped shield 6 itself around the electronics 4, which is open on one side. In this case, advantageously, the bottom of the housing adjoining the frame can also be covered with wall elements.

The cover 8, 8a may be suitable for hinges or others

Arrangements should be hinged. The cover 8, 8a of whatever shape may also be provided on the inside with platelets of magnetically shielding material. The cover 8, 8a covers the housing 3, the pot-like section 6 and also the secondary coil 2 and completes in the folded state an all-round shielding of the electronics 4 in the housing 3, which typically has a cuboid, preferably plate-like configuration towards the outside.

Finally, FIG. 3 shows by way of example an electrical circuit diagram of a secondary part of an inductive energy transmission system

Use of a transfer element 1, 1 a according to the invention. The secondary coil 2 arranged in or on the housing 3, 3a is connected to a rectifier circuit 15 via at least one capacitor 14. This is a terminal circuit 16 (English crowbar) connected as overvoltage protection for the rapid shutdown of the current flow in an emergency, further preferably an output filter 17 and finally the battery to be charged 5, for example, the traction battery of an electric vehicle. Via a control unit 18, parameters of said components are determined and their function controlled. Some or all of these components form the shielded electronics 4 of the transformer element. 1 LIST OF REFERENCE NUMBERS

1, 1 a transformer element

 2 secondary coil

 3 housing

 4 electronics

 5 battery

 6 pot-like section

6a bottom of section 6

 6b side walls of section 6

 7 open page

8, 8a cover

 9 potting compound

 12 connections for control and sensor cables

13 connections for battery 5

 14 capacity

 15 rectifier circuit

 16 clamp circuit (Crowbar)

 17 output filters

 18 electronic control unit 4

Claims

claims 1 . Transformer element (1, 1 a) for a system for contactless  Energy transfer between at least one primary part and at least one secondary part, comprising at least one coil (2) and electronics (4) and a connection (13) for a consumer and / or a battery to be charged (5), wherein at least one coil (2) and the electronics (4) are housed in a common housing (3), characterized in that the housing (3) comprises a pot-like section (6) of magnetically shielding material, preferably of ferrite, with at least one open side (7) or includes, and at least one secondary coil (2) surrounds the pot-like portion (6) on the outside thereof. 2. Transformer element according to claim 1, characterized in that the open side (7) of the housing (3) is at least partially provided with a cover (8) made of magnetically shielding material, preferably of aluminum. 3. transformer element according to claim 2, characterized in that between the cover (8, 8a) and the bottom and / or the  Side walls of the cup-like portion (6) at least part of the electronics (6) is surrounded by wall elements of magnetically shielding material. 4. transformer element according to one of claims 2 or 3, characterized  characterized in that a magnetically permeable region remains between the cover (8, 8a) and the open side (7) of the pot-like section (6) of the housing (3), preferably at least one coil (2) in and preferably below this permeable region is arranged. 5. transformer element according to at least one of claims 1 to 4, characterized in that at least one thermally conductive Element, preferably aluminum or copper plates, the housing (3) connects with at least one of the components arranged therein. 6. transformer element according to at least one of claims 1 to 5,  characterized in that the interior of the housing (3) comprises a potting compound (9) which preferably completely surrounds the components (e.g., 4) contained therein. 7. transformer element according to at least one of claims 1 to 6,  characterized in that the electronics (4) comprises a clamping circuit (16), preferably a rectifier circuit (15)  downstream and preferably an output filter 17th  upstream. 8. transformer element according to at least one of claims 1 to 7, as a secondary part for a system for contactless energy transfer between at least one primary part and at least one secondary part. 9. Transformer element according to claim 8, as on a vehicle  attached secondary part for supplying a  Energy storage system (5) of the vehicle. 10. System for contactless energy transfer between at least one primary part and a secondary part, preferably system for  Contactless charging of at least partially electrically operated vehicles, characterized in that the secondary part has at least one transformer element (1, 1 a) according to at least one of claims 1 to 8. 1 1. Vehicle with at least partially electric drive, preferably with a traction battery for feeding the electric drive with electrical energy, wherein the vehicle is the secondary part of a System for contactless energy transmission, characterized in that the vehicle is at least one secondary part Transmitter element (1, 1a) according to at least one of claims 1 to 8.