Method for the production of an inductive charging device

Abstract

A method for producing an inductive charging device may include inserting a ferrite and a coil, wound from a braid, into a mould; and encasing the ferrite and the braid at least partially with a plastic in a low pressure casting method, a pressing transfer moulding method, or an injection moulding method.

Claims

1. A method for the production of an inductive charging device, comprising: inserting a ferrite and a coil, wound from a braid, into a mould; inserting a carrier into the mould, on which the ferrite and the braid is arranged, wherein the carrier has clip connections for holding the braid in a coil shape; and at least partially encasing the ferrite and the braid with a plastic in a low pressure casting method, a pressing transfer moulding method, or an injection moulding method.

2. The method according to claim 1, wherein the ferrite and the braid are encased with the plastic with a pressure ranging from 5 bar to 100 bar.

3. The method according to claim 1, wherein the ferrite and the braid are encased with the plastic at a temperature of a maximum of 200° C.

4. The method according to claim 1, wherein the plastic includes one of a duromer, a silicone, an elastomer, a formaldehyde resin, or a reaction resin.

5. The method according to claim 1, wherein the carrier has openings for receiving the plastic during the at least partially encasing the ferrite and the braid with the plastic.

6. The method according to claim 1, wherein fluid channels are produced during the at least partial encasing of the ferrite and of the braid with plastic.

7. The method according to claim 1, wherein one of: a plastic plate or an aluminium plate is glued to the plastic once hardened; and a plastic plate or an aluminium plate is inserted into the mould and is connected with the plastic during the at least partial encasing of the ferrite and the braid.

8. The method according to claim 7, wherein a further plastic plate or a further aluminium plates is provided, wherein the plastic plate or the aluminium plate together with the further plastic plate or the further aluminium plate delimit internal fluid channels and a fluid inlet and a fluid outlet.

9. The method according to claim 7, wherein the plastic plate or the aluminium plate is flat and forms fluid channels together with the plastic of the inductive charging device.

10. An inductive charging device produced according to a method comprising: inserting a ferrite and a coil, wound from a braid, into a mould; inserting a carrier into the mould, on which the ferrite and the braid is arranged, wherein the carrier has clip connections for holding the braid in a coil shape; and at least partially encasing the ferrite and the braid with a plastic in a low pressure casting method, a pressing transfer moulding method, or an injection moulding method.

11. The inductive charging device according to claim 10, further comprising a plastic plate or an aluminium plate connected with the plastic.

12. The inductive charging device according to claim 11, further comprising a further plastic plate or a further aluminium plate, wherein the further plastic plate or the further aluminium plate together with the plastic plate or the aluminium plate delimit internal fluid channels and a fluid inlet and a fluid outlet.

13. The inductive charging device according to claim 10, wherein the plastic includes one of a duromer, a silicone, an elastomer, a formaldehyde resin, or a reaction resin.

14. The inductive charging device according to claim 10, wherein the carrier has openings for the plastic.

15. The inductive charging device according to claim 10, wherein fluid channels are are provided at least partially by the plastic.

16. The method according to claim 2, wherein the pressure ranges from 5 bar to 40 bar.

17. The method according to claim 4, wherein the plastic includes the formaldehyde resin, and the formaldehyde resin is a phenoplast or a melamine resin.

18. The method according to claim 4, wherein the plastic includes the reaction resin, and the reaction resin is an epoxy resin or an unsaturated polyester resin.

19. The method according to claim 6, wherein the fluid channels are produced by corresponding projections of the mould forming channel structures in the plastic.

20. The method according to claim 8, wherein the fluid channels are cooling channels, the fluid inlet is a coolant inlet, and the fluid outlet is a coolant outlet.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) There are shown, respectively diagrammatically,

(2) FIG. 1 shows a sectional illustration through an inductive charging device produced according to the prior art,

(3) FIG. 2 shows a sectional illustration through a mould in the production of an inductive charging device according to the invention,

(4) FIG. 3 shows an inductive charging device produced according to FIG. 2, with two plastic- or aluminium plates,

(5) FIG. 4 shows an illustration as in FIG. 2, but with a single plastic- or aluminium plate,

(6) FIG. 5 shows a sectional illustration through a carrier according to the invention, on which a braid is fixed,

(7) FIG. 6 shows a front and rear view of such a carrier.

DETAILED DESCRIPTION

(8) According to FIGS. 2 to 4, an inductive charging device 1, produced according to a method in accordance with the invention, is shown in a sectional illustration, wherein the inductive charging device 1 is produced as follows:

(9) Firstly, a ferrite 2 and a braid 3, which for example is wound in the form of a coil (cf. FIGS. 5 and 6), is inserted into a mould 4, similar to a plastic injection moulding tool. Subsequently, the ferrite 2 and the braid 3, which can also of course be several braids 3, are encased at least partially with plastic 5 in the low pressure casting method or in the pressing transfer moulding method or in the injection moulding method. Hereby, in particular a cycle time and, furthermore, also the production costs for the inductive charging device 1 can be distinctly reduced, just as for example occupational safety measures which are to be taken, such as suction devices for example, which were necessary in the conventional production of the inductive charging device 1′ (cf. FIG. 1) owing to the casting compounds 6′ containing solvent.

(10) The inductive charging device 1 according to the invention can be formed in particular so that it is suitable for the charging of electrically operated vehicles. The induction charging device 1 according to the invention can be arranged here in an electrically operated vehicle, wherein it is advantageous if the induction charging device 1 is arranged as close as possible to the travelling ground on which the vehicle moves. Hereby, the proportion of vehicle components which are penetrated by the chronologically varying magnetic field is minimized, whereby for example energy losses in the form of eddy currents are prevented.

(11) According to FIG. 1, an inductive charging device 1′ in accordance with the prior art is shown here in a sectional illustration, wherein all the reference numbers were used in an analogous manner to FIGS. 2 to 6, but were given an apostrophe. For the production of the inductive charging device 1′ firstly the ferrite 2′ and the braid 3′ are inserted into a housing 7′ and this housing 7′ is subsequently filled with the plastic 5′ or respectively the casting compound 6′ and via this the braid 3′ or respectively the ferrite 2′ is embedded into the plastic 5′. A disadvantage in this method, however, is that until further use a complete hardening of the plastic 5′ or respectively of the casting compound 6′ is to be awaited, which can last up to 24 hours. In addition, a housing 7′, to be produced separately and serving as lost formwork, is necessary, which can be dispensed with in the method according to the invention in accordance with FIGS. 2 to 4. As the casting compound 6′ usually also contains solvent, in addition special occupational safety measures such as suction devices, for example, must be provided. Also, a bubble-free casting is difficult in certain circumstances. In order to achieve a reliable anchoring of the casting compound 6′ in the housing 7′, in addition the housing 7′ must be pre-treated with an adhesion promoter or respectively a plasma method, which is also laborious and expensive. This can all be dispensed with in the method according to the invention.

(12) In accordance with the method according to the invention, the ferrite 2 and the braid 3 are encased with plastic 5 in the low pressure casting method, pressing transfer moulding method or injection moulding method with a pressure p of 5 bar≤p≤100 bar, preferably with only a pressure p of 5 bar≤p≤40 bar. Hereby, a gentle encasing of the ferrite 2 and of the braid 3 can be achieved, and a damage to these components can be reliably avoided. Furthermore, the ferrite 2 and the braid 3 are preferably encased with plastic 5 at a maximum temperature T of 200° C., whereby likewise a gentle embedding is possible.

(13) A duromer, a silicone, an elastomer, a formaldehyde resin, for example a phenoplast or a melamine resin, or a reaction resin, for example an epoxy resin or an unsaturated polyester resin, can be used for example as plastic 5. This non exhaustive list already gives an indication of what a varied use of plastics 5 is possible for the method according to the invention.

(14) For better fixing of the ferrite 3 and of the braid 2 in the mould 4, a carrier 8 (cf. FIGS. 5 and 6) can be used, for example, which is inserted into the mould 4 and on which the ferrite 2 and/or the braid 3 are able to be fixed. The braid 3 is, for example, wound in a spiral-shaped manner according to the right-hand illustration in FIG. 6 and is held via corresponding clip connections 9 on the carrier 8. The windings are substantially square here, but with greatly rounded corners. The ferrite 2 is also arranged on the carrier 8, so that it can also be held via the carrier 8. The left-hand illustration in FIG. 6 shows here the carrier 8 without braid 3 or respectively ferrite 2.

(15) Observing the embodiment of the inductive charging device 1 in accordance with the invention according to FIG. 3, it can be seen that there a plastic- or aluminium plate 10 has been glued with the hardened plastic 5 of the inductive charging device 1, or such a plastic- or aluminium plate 10 was firstly inserted into the mould 4 according to FIG. 2 and was connected there with the plastic 5 during the at least partial encasing of the ferrite 2 and/or of the braid 3. In FIG. 3, a further plastic- or aluminium plate 11 is also provided, which together with the plastic- or aluminium plate 10, connected with the plastic 5, delimits internal fluid channels, in particular cooling channels 12 and has a fluid inlet, in particular coolant inlet 13 and a fluid outlet, in particular coolant outlet 14.

(16) Alternatively to FIG. 3, according to FIG. 4 an embodiment is produced, in which during the encasing of the ferrite 2 and of the braid 3 with plastic 5, channel structures are produced for fluid channels, in particular cooling channels 12, by the mould 4 having corresponding projections. In this case, only a single flat plastic- or aluminium plate 10 has to be connected with the plastic 5 of the inductive charging device 1, in order to produce the fluid channels, in particular cooling channels 12. Hereby, a particularly preferred embodiment is created, in which only a single plastic- or aluminium plate 10 is necessary.

(17) Still observing FIG. 5, a carrier 8 can also be seen herein, on which a ferrite 2 and a braid 3 are arranged. The intermediate spaces are cast here with plastic 5. Such an inductive charging device 1 would be to be provided for equipping with fluid channels, in particular cooling channels, 12 with two plastic- or aluminium plates 10, 11. Via the fluid channels, cooling channels, 12, the inductive charging device 1 can be cooled.

(18) With the inductive charging device 1 according to the invention, not only can the production costs be distinctly reduced, likewise the cycle times for the production thereof, but also occupational safety measures which are to be taken if applicable, because in particular only solvent-free plastics 5 are used. Furthermore, the housing 7′ which was necessary in the prior art can also be dispensed with, likewise a pre-treatment thereof, in order to guarantee a necessary adhesion between the plastic 5′ or respectively the casting compound 6′ and the housing 7′.