Coil Unit for Inductively Charging a Vehicle, and System

Abstract

A coil unit inductively charges a vehicle. The coil unit has a housing and a coil. The coil is arranged at least partly in the housing. The coil has a plurality of windings of at least one electrical line, wherein the electrical line has two ends, and both ends of the electrical line are led out of the housing for connection to an electronic unit.

Claims

1. A coil unit for inductively charging a vehicle, comprising: a housing; a coil that is arranged at least partially in the housing, wherein the coil comprises a plurality of windings of at least one electrical line, wherein the electrical line has two ends, and both ends of the electrical line are led out of the housing for connecting to an electronic unit.

2. The coil unit as claimed in claim 1, wherein the electrical line comprises an HF braid.

3. The coil unit as claimed in claim 1, wherein a braided shield is arranged around the electrical line that is led out of the housing.

4. The coil unit as claimed in claim 3, wherein the housing comprises an outer side of metal, and the braided shield is connected to the outer side.

5. The coil unit as claimed in claim 3, wherein the coil unit comprises a ferrite component that is arranged at least partially in the housing, and the braided shield is connected to the ferrite component.

6. The coil unit as claimed in claim 5, wherein the braided shield is connected to the outer side or to the ferrite component by way of a flange.

7. The coil unit as claimed in claim 3, wherein one or a plurality of signal lines are arranged inside the braided shield.

8. The coil unit as claimed in claim 1, wherein the coil unit comprises a ferrite component which is arranged at least partially in the housing, the ferrite component has a recess, and one of the ends of the electrical line is led through the recess of the ferrite component out of the housing.

9. The coil unit as claimed in claim 1, wherein the ends of the electrical line are led out of the housing at an angle between 45 and 135.

10. The coil unit as claimed in claim 1, wherein the ends of the electrical line are led essentially straight out of the housing.

11. The coil unit as claimed in claim 1, further comprising: a plug for connecting to a socket of the electronic unit, wherein both ends of the electrical line are connected to the plug.

12. The coil unit as claimed in claim 11, further comprising: a strain relief that is connected to the plug and the coil unit.

13. The coil unit as claimed in claim 11, wherein the plug comprises a mechanism for electrical disconnection in an event of a separation of the plug-in connection.

14. The coil unit as claimed in claim 11, wherein the plug is configured such that, when in a plugged-in state, it has air and leakage gaps of >=15 mm.

15. A system for inductively charging a vehicle, comprising: a coil unit as claimed in claim 1; and the electronic unit.

16. The system as claimed in claim 15, wherein the electronic unit comprises a resonance capacitor.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0041] FIG. 1 shows a structure of an inductive charging system.

[0042] FIG. 2 shows a coil unit.

[0043] FIG. 3 shows the coil unit with the electrical line led out.

[0044] FIG. 4 shows the coil unit, wherein the ends of the electrical line are led out of the housing at an angle.

[0045] FIG. 5 shows the coil unit, wherein the ends of the electrical line are led essentially straight out of the housing.

[0046] FIG. 6 shows the coil unit with a recess in a ferrite component.

[0047] FIG. 7 shows the system with the coil unit and an electronic unit.

[0048] FIG. 8 shows a plug.

[0049] FIG. 9 shows the plug in an open position.

[0050] FIG. 10 shows the plug in an inserted position.

[0051] FIG. 11 shows an assembly of coil unit and braided shield.

[0052] FIG. 12 shows a cross-section of the electrical line with braided shield.

DETAILED DESCRIPTION OF THE DRAWINGS

[0053] Elements of the same construction or function are identified with the same reference signs across the figures.

[0054] FIG. 1 shows a structure of an inductive charging system. The charging system consists of a base unit 100 and a vehicle unit 200 that is connected to a vehicle battery 300.

[0055] The base unit 100 has a voltage source 101, an inverter 103, a compensation unit 105, and a resonant circuit 107.

[0056] The voltage source 101 is designed to make a voltage U.sub.DC available.

[0057] The compensation unit 105 comprises, for example, a filter. The resonant circuit 107 includes a resonance capacitor and a primary coil L1.

[0058] The vehicle unit 200 has a resonant circuit 201, a compensation unit 203 and a rectifier 205 that is connected to the vehicle battery 300 for charging the vehicle battery 300.

[0059] The compensation unit 203 of the vehicle unit 200 comprises, for example, a filter. The resonant circuit 201 of the vehicle unit 200 also includes a resonance capacitor and a secondary coil L2.

[0060] During a charging process, the secondary coil L2 and the primary coil L1 have an inductive coupling k.

[0061] The compensation unit 203 of the vehicle unit 200, the resonance capacitor of the vehicle unit 200, and the rectifier 205 can also be referred to as secondary electronics.

[0062] FIG. 2 shows a coil unit 1 for inductively charging a vehicle. The coil unit 1 has a housing 3. The coil unit 1 furthermore has a coil 5 that is arranged at least partially in the housing 3. The coil 5 is, in particular, the secondary coil L2.

[0063] The coil 5 comprises a plurality of windings of at least one electrical line 7. The electrical line 7 comprises, for example, an HF braid; in particular the electrical line 7 is an HF braid.

[0064] The coil unit 1 furthermore has a ferrite component 9. The ferrite component 9 can also be referred to as the ferrite core of the coil 5. The ferrite component 9 is arranged at least partially in the housing 3.

[0065] The housing 3 is formed in particular on the inside of plastic and has an outer side 31 of metal, in particular for screening upward, i.e. in the direction toward the vehicle. The outer side of the housing 3 is not of metal in the direction toward the ground.

[0066] FIG. 3 shows the coil unit 1 with the electrical line 7 led out. The electrical line 7 has two ends 71, 73. Both ends 71, 73 of the electrical line 7 are led out of the housing 3 for connecting to an electronic unit 80 (which is explained later in more detail). The electrical line 7 is, in other words, led out of the housing 3 as one piece. This means that there is no plug-in contact or other interruption of the electrical line 7.

[0067] In FIG. 3, a braided shield 10 is arranged around the part of the electrical line 7 that is led out of the housing 3 to screen the electrical line 7 electromagnetically.

[0068] The braided shield 10 is fastened in FIG. 3 to the outer side 31 of the housing 3. This is possible when the housing 3 has an outer side 31 of metal. The braided shield 10 can also, alternatively, be fastened to the ferrite component 9.

[0069] The electrical line 7 can be led out of the housing 3 in a variety of ways.

[0070] The ends 71, 73 of the electrical line 7 are, for example, led out of the housing 3 at an angle between 45 and 135. The ends 71, 73 of the electrical line 7 are in particular led out of the housing 3 at an angle of essentially 90, as shown in FIG. 4. Essentially here means, for example, 5.

[0071] The legs of the angle are here in particular a first axis that extends along the respective coil winding in the region in which the electrical line 7 is led out, and a second axis that extends essentially in the direction in which the ends 71, 73 of the electrical line 7, that have been led out, essentially extend, after a first bend in relevant cases.

[0072] The ends 71, 73 of the electrical line 7 are alternatively led essentially straight out of the housing 3, as shown in FIG. 5. Essentially here means, for example, 5.

[0073] FIG. 6 shows a space-saving possibility for leading in particular an inner end 71 of the electrical line 7 out of the housing 3. The ferrite component 9 has for this purpose a recess 91 and one of the ends 71, 73 of the electrical line 7, that is in particular the inner end 71, is led through the recess 91 of the ferrite component 9 out of the housing 3.

[0074] FIG. 7 shows a system 50 with the coil unit 1 and the electronic unit 80. The electronic unit 80 comprises in particular the secondary electronics, that is the resonance capacitor of the vehicle unit 200, the compensation unit 203 of the vehicle unit 200 and the rectifier 205. The electronic unit 80 is in addition connected to the vehicle battery 300 to charge the vehicle battery 300.

[0075] To connect the coil unit 1 to the electronic unit 80, a socket 81 is provided in particular at the electronic unit 80, and the ends 71, 73 of the electrical line 7 are connected to a plug 20 for connection at the socket 81.

[0076] In addition, a strain relief is optionally provided which is connected to the plug 20 and the coil unit 1. The strain relief can also, for example, be realized through the braided shield 10.

[0077] FIGS. 8, 9 and 10 show an embodiment of the plug 20.

[0078] The plug 20 includes a mechanism 21 for electrical disconnection in the event of a separation of the plug-in connection. Such a mechanism 21 is, for example, a hardware circuit provided for this purpose, first-mate contacts, an HV interlock, or the like.

[0079] The plug 20 is, by way of example, designed such that when in the plugged-in state (FIG. 10), it has air and leakage gaps 90 of 15 mm, in particular 20 mm. The air and leakage gaps 90 can be shorter in the unplugged state (FIG. 9). For the long air and leakage gaps 90 in the plugged-in state, the plug 20 has, for example, at least one recess 23a, 23b, 23c that is arranged radially outside a plug-in contact of the electrical line 7. The socket 81 comprises a complementary piece 83a, 83b, 83c that matches the recesses 23a, 23b, 23c. As a result, air must first travel approximately around the inner circumference of the recesses 23a, 23b, 23c before it can emerge from the plug 20.

[0080] FIG. 11 shows a possible procedure for assembly of the coil unit 1. The electrical line 7 that is led out of the housing 3 is introduced into the braided shield 10. The braided shield 10 is then fastened to the coil unit 1. The braided shield 10 has, for example, a flange 95 for this purpose, by which the braided shield 10 can be fastened to the coil unit 1, that is in particular to the outer side 31 and/or to the ferrite component 9. The flange 95 is fastened, for example, by use of screws.

[0081] FIG. 12 shows a cross-section of the electrical line 7 with the braided shield 10. One or a plurality of signal lines 75a, 75b, 75c, 75d are for example additionally arranged in the braided shield 10, for example two or four signal lines 75a, 75b, 75c, 75d.

[0082] Since the coil unit 1 and the electronic unit 80 are two separate components, all the delicate electronic parts can be installed at another location in the vehicle, as a result of which the installation space can be used more efficiently and the coil unit is more robust. In that both ends 71, 73 of the electrical line 7 are led out of the housing 3, the high frequencies and voltages do not have to be led to the electronic unit 80 over conventional cable connections. The safety and efficiency during a charging process can thereby be increased, and a more compact and robust structure ensured at the same time.

LIST OF REFERENCE SIGNS

[0083] 1 Coil unit [0084] 3 Housing [0085] 5 Coil [0086] 7 Electrical cable [0087] 9 Ferrite component [0088] 10 Braided shield [0089] 20 Plug [0090] 21 Mechanism [0091] 23a, b, c Recesses [0092] 31 Outer side [0093] 50 System [0094] 71 End of the electrical line [0095] 73 End of the electrical line [0096] 75a, b, c, d Signal lines [0097] 80 Electronic unit [0098] 81 Socket [0099] 83a, b, c Complementary pieces [0100] 90 Air and leakage gaps [0101] 91 Recess [0102] 95 Flange [0103] 100 Base unit [0104] 101 Voltage source [0105] 103 Inverter [0106] 105 Compensation unit [0107] 107 Resonant circuit [0108] 200 Vehicle unit [0109] 201 Resonant circuit [0110] 203 Compensation unit [0111] 205 Rectifier [0112] 300 Vehicle battery [0113] UDC Voltage [0114] L1 Primary coil [0115] L2 Secondary coil [0116] k Coupling

[0117] The foregoing disclosure has been set forth merely to illustrate the invention and is not intended to be limiting. Since modifications of the disclosed embodiments incorporating the spirit and substance of the invention may occur to persons skilled in the art, the invention should be construed to include everything within the scope of the appended claims and equivalents thereof.