INSTALLATION AID CHAIN, INSTALLATION AID CHAIN, COIL ARRANGEMENT WITH THE SAME, AND METHOD FOR PRODUCING A COIL ARRANGEMENT FOR A VEHICLE-SIDE INDUCTION CHARGING UNIT CHARGING UNIT WITH AN INSTALLATION AID CHAIN

Abstract

An installation aid chain member for an installation aid chain may be arranged for positioning and fixing an electric conductor. The installation aid chain member may include a base, at least one coupling arrangement, and a conductor holder. The base may define a support surface. The support surface may support or be able to support the installation aid chain member. The at least one coupling arrangement may be arranged on the base for movably coupling the installation aid chain member to a second installation aid chain member. The conductor holder may be arranged away from the support surface on the base, for retaining a conductor portion of the electric conductor.

Claims

1. An installation aid chain member for an installation aid chain, the installation aid chain arranged for positioning and fixing an electric conductor , comprising: a base defining a support surface, the support surface at least one of supporting and able to support the installation aid chain member; at least one coupling arrangement (12, 13) arranged on the base for movably coupling the installation aid chain member to a second installation aid chain member; and a conductor holder, the conductor holder arranged away from the support surface on the base, for retaining a conductor portion of the electric conductor.

2. The installation aid chain member according to claim 1, wherein: the conductor holder includes at least one holding portion for receiving and retaining the conductor portion of the electric conductor; and at least one of: the at least one holding portion (15, 16) is a recess mount, curved in a concave manner and on a recess support surface, the conductor portion of the electric conductorarranged in the recess mount; the at least one holding portion is a two-winged clamp including two clamping wings, the two clamping wings lying opposite one another and at least one of delimiting and forming a clamping mount, the conductor portion of the electric conductor insertable into the clamping mount, and wherein when the conductor portion of the electric conductor is inserted into the clamping mount, the clamping wings lie in a touching manner on the conductor portion of the electric conductor and clamp the electric conductor; and the at least one holding portion is a u-shaped groove with an undercut, coordinated in a precisely fitting manner to the conductor portion of the electric conductor.

3. The installation aid chain member according to claim 2, wherein: the at least one holding portion is arranged for receiving and retaining the conductor portion of the electric conductor such that electric conductors of different conductor cross-sections can be received and retained.

4. The installation aid chain member according to claim 1, wherein: the at least one coupling arrangement is at least one of (i) formed integrally with the base and (ii) is provided as a separate component and is arranged on the base.

5. The installation aid chain member according to claim 1, wherein: the installation aid chain member includes two coupling arrangements arranged on base end faces of the base, the base end faces oriented opposed to one another.

6. The installation aid chain member according to claim 5, characterized wherein: the two coupling arrangements are at least one of (i) formed in a complementary manner to one another, and (ii) at least one of coupled and are able to be coupled respectively to a complementary coupling arrangement (12, 13) of the second installation aid chain member in at least one of a form-fitting and force-fitting manner.

7. The installation aid chain member according to claim 5 , wherein: at least one of: a first coupling arrangement of the two coupling arrangements is an external circular cylinder plate projecting with respect to the base, and a second coupling arrangement of the two coupling arrangements is an external circular cylinder plate mount projecting with respect to the base; a first coupling arrangement of the two coupling arrangements is an external ball bar projecting with respect to the base, and a second coupling arrangement of the two coupling arrangements is an external ball bar mount projecting with respect to the base; and a first coupling arrangement of the two coupling arrangements is an external ball hook projecting with respect to the base, and a second coupling arrangement of the two coupling arrangements is an external ball hook mount projecting with respect to the base.

8. The installation aid chain member according to claim 5 , wherein: the two coupling arrangements define in their main extent direction a laying direction of the installation aid chain member, wherein the base end faces are oriented perpendicularly with respect to the laying direction; a first coupling arrangement of the two coupling arrangements is external to the base and is arranged in at least one of in and in the region of a base end face centre on a first base end face of the two base end faces on the base; and a second coupling arrangement of the two coupling arrangements is internal to the base and is arranged in the base and opens out in at least one of in and in the region of a base end face centre on a second base end face of the two base end faces (27, 29).

9. The installation aid chain member according to claim 8, wherein: the first coupling arrangement includes a bar-shaped coupling projection arranged on the first base end face on the base, and a coupling element able to be movably coupled to a coupling counter-element , wherein the coupling projection projects over the first base end face in the direction of the laying direction and carries the coupling element at a free end; and the second coupling arrangement includes a coupling counter-element arranged internally in the base and is able to be movably coupled to a coupling element, andincludes a connecting neck opening out at the second base end faceand at the coupling counter-element, cooperating with a coupling projection.

10. The installation aid chain member according to claim 9, wherein: the coupling elementis at least one of a sphere, an ovoid , and a circular cylinder plate; and the coupling counter-elementis at least one of (i) a spherical recess, open on one side, and formed integrally into the base,(ii) a hemispherical recess, open on one side, and formed integrally into the base, and (iii)a circular cylinder plate recess, open on one side, and formed integrally into the base.

11. The installation aid chain member according to claim 9, wherein: at least one of the coupling counter-elementand the connecting neckof the second coupling arrangement includes elastic characteristics.

12. The installation aid chain member according to claim 1, wherein: the installation aid chain member is at least one of: plurality of partssuch that the base, the at least one coupling arrangement and the conductor holder are separate individual components and are joined together at least one of detachably or non-detachably; partially monolithic such that the base and the at least one coupling arrangement are formed jointly in a single primary shaping step, and the conductor holder is a separate individual component and is joined at least one of detachably and non-detachably to the base ; and monolithic such that the base and the at least one coupling arrangement and the conductor holder are formed jointly in a single primary shaping step.

13. An installation aid chain for positioning and fixing an electric conductor on a mounting area of an induction charging unit for a motor vehicle, comprising: at least one of: a base and at least one conductor holder for retaining a conductor portion of the electric conductor; and a plurality of installation aid chain members coupled to one another, according to claim 1; and wherein the plurality of installation aid chain members includes installation aid chain members forming a free chain end of the installation aid chain , the respective installation aid chain members include a single coupling arrangement, and the remaining installation aid chain members of the plurality of installation aid chain members include two coupling arrangements.

14. A coil arrangement of an induction charging unit for a motor vehicle, comprising: at least one installation aid chain according to claim 13, arranged in a shape contour of a flat spiral on a mounting area of the induction charging unit ; wherein on the installation aid chain, an electric conductor following the shape contour thereof, is arranged and retained, which forming a flat coil; and a cast body at least one of partially and entirely enveloping and fixing the electric conductor and the installation aid chain members of the installation aid chain, the cast body applied in a liquid processing state onto the electric conductor and the installation aid chain members of the installation aid chain, and is hardened.

15. A method for producing a coil arrangement for an induction charging unit of a motor vehicle according to claim 14, wherein: a coil arrangement is provided with a spacer grid arranged between the flat coil and magnetic field conductor elements for conducting a magnetic field; and the spacer grid is provided with clearance passages, such that in production of the coil arrangement, a cast body is provided in liquid processing state and is applied and penetrates through the clearance passages.

16. An installation aid chain member for an installation aid chain, comprising: a base defining a support surface, the support surface supporting the installation aid chain member; at least one coupling arrangement arranged on the base for coupling the installation aid chain member to a second installation aid chain member; and a conductor holder arranged away from the support surface on the base and for retaining a conductor portion of the electric conductor, the conductor holder including at least one holding portion for receiving and retaining the conductor portion of the electric conductor.

17. The installation aid chain member of claim 16, wherein: the at least one holding portion is a concave recess mount arranged on a recess support surface, the conductor portion of the electric conductor arranged in the recess mount.

18. The installation aid chain member of claim 16, wherein: the at least one holding portion is a two-winged clamp including two clamping wings, the two clamping wings forming a clamping mount; and the conductor portion of the electric conductor is insertable in the clamping mount, the two clamping wings lying on the conductor portion and clamping the electric conductor.

19. The installation aid chain member of claim 16, wherein: the at least one holding portion is a u-shaped groove including an undercut; and the u-shaped groove is form-fitting to the conductor portion of the electric conductor.

20. The installation aid chain member of claim 16, wherein: the at least one coupling arrangement is formed integrally with the base.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0058] There are shown, respectively schematically

[0059] FIG. 1 shows a front view of a preferred example embodiment of an installation aid chain member according to the invention,

[0060] FIG. 2 shows a side view of an installation chain aid member of FIG. 1 according to an arrow II drawn there,

[0061] FIG. 3 shows a top view of the installation aid chain member of FIG. 1 according to an arrow III drawn there,

[0062] FIG. 4 shows in a top view, an installation aid chain composed of a plurality of installation aid chain members according to FIG. 1,

[0063] FIG. 5 shows in a top view, a portion of the installation aid chain of FIG. 4, but this is laid into a shape contour in the manner of a flat coil,

[0064] FIG. 6 shows a top view of the installation aid chain member of FIG. 1 according to an arrow III drawn here, but with an inserted position-securing element,

[0065] FIG. 7 shows an installation aid chain composed of a plurality of installation aid chain members according to a preferred further example embodiment,

[0066] FIG. 8 shows an installation aid chain composed of a plurality of installation aid chain members according to a preferred further example embodiment,

[0067] FIG. 9 shows an installation aid chain composed of a plurality of installation aid chain members according to a preferred further example embodiment,

[0068] FIG. 10 shows a coil arrangement of flat coil and installation aid chain, which is arranged in a vehicle-side induction charging unit of a motor vehicle,

[0069] FIGS. 11 to 15 show further installation aid chains according to different example embodiments.

DETAILED DESCRIPTION

[0070] FIGS. 1 to 3 show a preferred example embodiment of an installation aid chain member, designated as a whole by reference number 1, firstly in a front view, then in a side view according to an arrow II drawn in FIG. 1 and lastly in a top view according to an arrow III, also drawn in FIG. 1.

[0071] The installation aid chain member 1 according to the invention in accordance with FIGS. 1 to 3 has a base 10 which is formed by way of example by a cuboid-shaped flat body 49, which in its main extent direction 50 defines a base length 51 and, transversely to the main extent direction 50 in a transverse direction 52 defines a base width 53, cf. FIG. 3. The base 10 or respectively the planar body 49 defines a support surface 11, via which in installation aid chain member 1 is supported on a mounting area 5, indicated in FIGS. 1 and 2 by a dashed line, of an induction charging unit 9, not illustrated here, for a motor vehicle, which is also not illustrated. On the base 10 two integral coupling arrangements 12, 13 are provided, which serve for the movable coupling of the installation aid chain member 1 with at least one further installation aid chain member 57, 58 and are designated in the following, for simpler description, as first coupling arrangement 12 and second coupling arrangement 13. The installation aid chain member 1 has, furthermore, an integral conductor holder 14, arranged away from the support surface 11 on the base 10, which conductor holder retains, i.e. receives and fixes, a conductor portion 3, only partially illustrated in FIGS. 2 and 3, of an electric conductor 2 with a predetermined conductor cross-section 4.

[0072] The said conductor holder 14 has according to the example embodiment in accordance with FIGS. 1 to 3 a holding portion 15 for receiving and retaining the conductor portion 3 of the electric conductor 2, wherein by way of example provision is made that the holding portion 15 is realized by a two-winged clamp 21. Between the two clamping wings 22, 60, lying opposite with respect to one another, of the clamp 21 an internal clamping mount 23 is delimited, cf. FIG. 1, into which the conductor portion 3 of the electric conductor 2 is inserted here entirely, so that the clamping wings 22, 60 lie touching on the conductor portion 3 of the electric conductor 2 and clamp the electric conductor 2. Alternatively or additionally, the conductor portion 3 of the electric conductor 2 can also be fixed on the clamp 21 by means of an adhesive, which is not shown. At least one of the clamping wings 22, 60 has a slitting 24, which is directed transversely to the electric conductor 3 and simplifies the elastic clamping process.

[0073] According to the example embodiment in accordance with FIG. 10, the said conductor holder 14 can have, alternatively, a holding portion 15 for receiving and retaining the conductor portion 3 of the electric conductor 2, which is realized by a recess mount 19, curved in a concave manner, on the recess support surface 20 of which the conductor portion 3 of the electric conductor 2 is received and fixed and preferably bonded adhesively.

[0074] According to the example embodiment in accordance with FIG. 7 the said conductor holder 14 can have two separate holding portions 15, 16, wherein both holding portions 15, 16 can either be realized as recess mount 19 with recess support surface 20 or as a clamp 21 with clamping wings 22, 60.

[0075] In each case, the conductor holder 14 has, however, at least one support portion 25, which on the one hand is formed integrally on the at least one holding portion 15, 16 and on the other hand is either inserted on the base 10 or is likewise formed integrally therewith, so that the holding portion or respectively holding portions 15, 16 can rest on the base 10 via the support portion 25. The support portion 25 expediently defines here a holding portion-base distance 2, standing on the base 10 or respectively to be measured perpendicularly, which distance can be varied by a predetermined or predeterminable support portion component height of the support portion 25. Thereby, as it were, the installation aid chain member 1 can carry the conductor portion 3 of the electric conductor 2 with a predetermined or predeterminable distance with respect to a mounting area 5 of an induction charging unit 9.

[0076] The two said coupling arrangements 12, 13 are arranged on base end faces 27, 29 of the base 10 oriented opposed to one another, define in their main extent direction a so-called laying direction 37 and are formed in a complementary manner to one another, so that on both sides of the installation aid chain member 1 further installation aid chain members 57, 58 can be coupled in a form-fitting and/or force-fitting manner with complementary coupling arrangements, respectively matching thereto, cf. in particular FIG. 4.

[0077] According to the example embodiment in accordance with FIGS. 1 to 3, provision is made that the first coupling arrangement 12 of these two coupling arrangements 12, 13 has a bar-shaped or cone-shaped coupling projection 38, which is arranged on the first base end face 27 at its base end face centre 28 and projects over the first base end face 27 in the direction of the laying direction 37. The coupling projection 38 carries at its free end 39, facing away from the base end face 27 a coupling element 40 of the coupling arrangement 12, realized by a circular cylinder plate 31, which can be movably coupled with a coupling counter-element 41 of a further installation aid chain member 57, 58, configured in a complementary manner, realized by a circular cylinder plate recess 32.

[0078] The second coupling arrangement 13 of these two coupling arrangements 12, 13 is configured in a complementary manner to the first coupling arrangement 12 and has, for this, a coupling counter-element 41, arranged internally in the base 10, able to be movably coupled to a coupling element 12 of a further installation aid chain member 57, 58, and has a connecting neck 42, opening out on the one hand for instance in the base end face centre 30 on the second base end face 29 and on the other hand on the coupling counter-element 41. The coupling counter-element 41 is formed by way of example by a circular cylinder plate recess 32, formed integrally into the base 10, open on one side to the base surface 11, wherein for securing a circular cylinder plate 31 (coupling element 40) inserted therein, of a further installation aid chain member 57, 58, a position-securing element 48 is provided, inserted into the coupling counter-element 41 and/or into the connecting neck 42, cf. FIG. 6. Thereby, an unintentional disengaging of the installation aid chain members 1, 57, 58 can be efficiently prevented.

[0079] According to the example embodiment in accordance with FIG. 7, provision is made that the first coupling arrangement 12 is realized by an external circular cylinder plate 31, projecting outwards with respect to the base 10, and the second coupling arrangement 13 is realized by a likewise external circular cylinder plate mount 59, projecting outwards with respect to the base 10.

[0080] According to the example embodiment in accordance with FIG. 8, provision is made that the first coupling arrangement 12 is formed by an external ball bar 32, projecting outwards with respect to the base 10, and the second coupling arrangement 13 is formed by an external ball bar mount 34, projecting outwards with respect to the base 10. By way of example, the ball bar mounts 34 and/or the ball bars 33 are equipped respectively with a said position-securing element 48.

[0081] According to the example embodiment in accordance with FIG. 9, provision is made that the first coupling arrangement 12 is realized by an external ball hook 35, projecting outwards with respect to the base 10, and the second coupling arrangement 13 is realized by an external ball hook mount 36, projecting outwards with respect to the base 10. The ball head of the ball hook 35 can be seen here cranked upwardly, whereas the ball hook mount 36 is cranked downwardly or at least is downwardly open.

[0082] FIGS. 4 and 5 show respectively in a top view an installation aid chain 6 composed of numerous installation aid chain members 1, 57, 58 according to the example embodiment in accordance with FIGS. 1 to 3. The installation aid chain 6 is laid in accordance with FIG. 4 into a curve, and the installation aid chain 6 is laid in accordance with FIG. 5 into a shape contour 7 in the manner of a flat coil, the latter is, however, only partially illustrated. The installation aid chain members 1, 57, 58 of the installation aid chain 6 are movably coupled with one another here so that they can be displaced relative to one another for example to the sides, which is indicated in FIG. 4 with an angle □, and/or upwards and downwards, which is indicated in FIG. 9 with an angle □. Thereby, with an installation aid chain 6 optionally a flat curve shape or flat spiral shape or alternatively a three-dimensional curve shape or three-dimensional spiral shape, therefore as it were a vertical topology can be depicted. Thereby, the installation aid chain 6 can be laid at practically any contour of a mounting area 5 of an induction charging unit 9, practically without expenditure of force and relatively flexibly into a predetermined shape contour 7, for example into a spiral shape, and can be positioned via the support surfaces 11 of the bases 10 of its installation aid chain members 1, 57, 58 on the same mounting area 5 and can be fixed there if applicable with an adhesive. Thereby, a preferred installation aid chain 6 is indicated, which is composed of a plurality of installation aid chain members 1, 57, 58. In order to be able to position and fix an electric conductor 2 on a mounting area 5 of an induction charging unit 9 of a motor vehicle, provision is made that an electric conductor 2, for example an individual wire or a multi-core stranded wire, is arranged and retained on the installation aid chain members 1, 57, 58 in the conductor holders 14 thereof. Thereby, the electric conductor 2 can follow or respectively take over the shape contour 7 predetermined by the installation aid chain 6, so that on the mounting area 5 of the induction charging unit 9 by way of example, with regard to FIG. 5, a flat coil 8 is realized.

[0083] FIG. 10 shows a housing, not to be designated more closely, of an induction charging unit 9 with mounting area 5, wherein within the housing a coil arrangement 54 is arranged, which is equipped with a flat coil 8 provided with an installation aid chain 6 and an electric conductor 2, a spacer grid 56 and magnetic field conductor elements 61. The installation aid chain 6 and the electric conductor 2 are arranged in a spiral-shaped shape contour 7, which can not be seen here, so that the flat coil 8 as a whole is given a shape in the manner of a flat spiral. The magnetic field conductor elements 61 have the purpose of optimizing the magnetic characteristics of the flat coil 8, wherein by means of the spacer grid 56, which is arranged in a sandwich-like manner between the flat coil 8 and the magnetic field conductor elements 61, a predetermined distance can be set between the magnetic field conductor elements 61 and the flat coil 8. In FIG. 10 it can be seen furthermore that the coil arrangement 54 is embedded in a cast body 55. This cast body 55, in particular an epoxy resin, is applied on mounting of the coil arrangement 54 in a liquid processing state onto the electric conductor 2, the installation aid chain 6, the magnetic field conductor elements 61 and the spacer grid 56, so that these are at least partially or preferably completely wetted, and is subsequently hardened. Thereby, the components of the coil arrangement 54 are enveloped all around and are fixed to one another, whereby the coil arrangement 54 for example is more resistant with respect to impacts and environmental influences. So that the still liquid cast body 55 can wet the coil arrangement 54 as completely as possible during mounting, the spacer grid 56 is equipped with clearance passages through which the still liquid cast body 55 can flow. Expediently, through the adaptation of the shape contour 7 of the installation aid chain 6 for example the number of coil windings and/or the length of the electric conductor 2 can be predetermined, so that the electromagnetic characteristics of the flat coil 8 can be set within wide ranges. Thereby, further components of the induction charging unit 8, in particular a power electronics, communication electronics, safety electronics, electric connections, cooling connections and other necessary components of the induction charging unit can be maintained unchanged structurally, whereby the induction charging unit 9 is able to be produced in a relatively favourable manner and/or is able to be adapted to changing boundary conditions.

[0084] FIGS. 11 to 15 illustrate further preferred example embodiments for installation aid chains 6 for positioning and fixing an electric conductor 2 on a mounting area 5 of an induction charging unit 9 of a motor vehicle. These installation aid chains 6 have altogether a foundation designated as base 10, and at least one conductor holder 14, arranged thereon, for retaining a conductor portion 3 of an electric conductor 2. Base 10 and conductor holder 14 can be embodied integrally or separately here.

[0085] According to FIG. 11 provision can be made that the base 10 and the conductor holder 14 are realized integrally by a bent plastic wire (e.g. PP, PA, or similar), which has reciprocal ring holding structures for constituting the conductor holder 14. According to FIG. 12 provision is made that the base 10 and the conductor holder 14 are formed by two separate elastomer bands which are expediently interwoven with one another or are clipped into one another. Each of these elastomer bands can preferably form a portion of the base 10 and of the conductor holder 14. According to FIGS. 13 and 14 provision is made by way of example that base 10 and the conductor holder 14 are produced integrally by a single component, namely by an elastomer band (injection moulding cross-section). According to FIG. 15 for example provision is made that the base 10 is realized by way of example by a perforated elastomer band and the conductor holder 14 is formed by numerous c-shaped plastic clip structures which are inserted into the perforated openings of the elastomer band.