Ground assembly for an inductive charging device

Patent metadata

Field	Value
Publication number	US-12580418-B2
Application number	US-202217961492-A
Country	US
Kind code	B2
Filing date	Oct 6, 2022
Priority date	Oct 7, 2021
Publication date	Mar 17, 2026
Grant date	Mar 17, 2026

Abstract

A ground assembly for an inductive charging device for inductively charging a motor vehicle parked on a surface may include a base plate, a flat coil, a core arrangement, a lower hollow space, a support, and a heat conducting element. The flat coil may be arranged spaced apart from the base plate. The core arrangement may be arranged between and spaced apart from the base plate and a helically wound conductor of the flat coil. The support may be disposed between a core body of the core arrangement and the base plate, and may extend through the lower hollow space. The flat coil may include a stranded wire carrier, which may include a pressure pedestal arranged co-axially to the support. The heat conducting element may at least partially surround the pressure pedestal and may connect the stranded wire carrier with the core body in a heat-transmitting manner.

First claim

The invention claimed is:

1 . A ground assembly for an inductive charging device for inductively charging a motor vehicle parked on a surface, the ground assembly comprising:
a base plate extending plate-like transversely to a distance direction; at least one flat coil including a helically wound conductor, the at least one flat coil arranged spaced apart from the base plate in the distance direction; a core arrangement for magnetic flux control, the core arrangement disposed spaced apart from the base plate and from the at least one flat coil in the distance direction and arranged between the base plate and the conductor; the core arrangement including at least one core body extending plate-like transversely to the distance direction; a lower hollow space formed between the at least one core body and the base plate; at least one support disposed between the at least one core body and the base plate, the at least one support extending through the lower hollow space in the distance direction; the at least one support formed of a material having a heat conductivity that is greater than 5 W/(m·K); the at least one flat coil further including a stranded wire carrier, which includes at least one pressure pedestal arranged co-axially to the at least one support, via which the stranded wire carrier is supported on the at least one core body of the core arrangement; and a heat conducting element at least partially surrounding the at least one pressure pedestal and connecting the stranded wire carrier with the at least one core body in a heat-transmitting manner.

2 . The ground assembly according to claim 1 , wherein the base plate is a cooling plate including a plurality of cooling channels.

3 . The ground assembly according to claim 1 , wherein:
the heat conducting element includes a plurality of thermally conductive particles embedded in a plastic; and the plastic has a shore hardness that is less than 10.

4 . The ground assembly according to claim 1 , wherein the at least one support is at least partially formed of at least one of graphite, a ceramic, and a metal.

5 . The ground assembly according to claim 1 , wherein:
the heat conducting element includes a plurality of recesses; and at least one of a density and a size of the plurality of recesses increases with increasing distance from the at least one pressure pedestal.

6 . The ground assembly according to claim 1 , wherein the heat-conducting element is a perforated film formed as a separate, independent component.

7 . The ground assembly according to claim 1 , wherein the stranded wire carrier further includes an upper stranded wire carrier and a lower stranded wire carrier between which the at least one flat coil is arranged.

8 . The ground assembly according to claim 7 , wherein the conductor of the at least one flat coil is at least partially surrounded by a heat-conducting sheath.

9 . The ground assembly according to claim 7 , wherein:
the conductor of the at least one flat coil penetrates the lower stranded wire carrier; an electrically insulating layer is arranged between the conductor and the at least one core body; and the electrically insulating layer has a dielectric strength that is greater than 10 kV.

10 . The ground assembly according to claim 1 , further comprising a stranded wire holder composed of a plastic, wherein:
the stranded wire holder holds the conductor; the stranded wire holder and the conductor are completely embedded in a plastic matrix; and the conductor is covered with a coating that increases heat conduction and adhesion to the plastic matrix.

11 . The ground assembly according to claim 1 , further comprising a distributor plate arranged between the at least one support and the at least one core body, wherein the distributor plate is connected with the at least one core body via an adhesive layer composed of a material having at least one of:
a heat conductivity that is greater than 0.8 W/(m·K); and a shear modulus that is less than 10 MPa.

12 . The ground assembly according to claim 1 , further comprising a plurality of positioning elements arranged on the stranded wire carrier for fixing a position of the at least one core body transversely to the distance direction.

13 . The ground assembly according to claim 1 , wherein at least one of:
an air flow path extends through the lower hollow space; and at least one electronic component is arranged in the lower hollow space.

14 . The ground assembly according to claim 1 , further comprising:
a cover plate disposed on a side of the at least one flat coil facing away from the base plate and disposed spaced apart from the at least one flat coil in the distance direction; and a circuit board arranged between the at least one flat coil and the cover plate.

15 . The ground assembly according to claim 1 , wherein the heat conducting element includes a plurality of recesses that are arranged evenly distributed.

16 . The ground assembly according to claim 1 , wherein the heat-conducting element is screen-printed onto at least one of the stranded wire carrier and the at least one core body.

17 . The ground assembly according to claim 3 , wherein the plastic is silicone.

18 . The ground assembly according to claim 9 , wherein:
the electrically insulating layer is an insulation film; and the dielectric strength of the electrically insulating layer is greater than 20 kV.

19 . A ground assembly for an inductive charging device for inductively charging a motor vehicle parked on a surface, the ground assembly comprising:
a base plate; a flat coil including a helically wound conductor and a stranded wire carrier; a magnetic flux controlling core arrangement including a core body; a support extending between the core body and the base plate such that a lower hollow space is defined between the core body and the base plate, the support having a heat conductivity that is greater than 5 W/(m·K); the stranded wire carrier including a pressure pedestal protruding therefrom co-axially to the support, the pressure pedestal supporting the stranded wire carrier on the core body such that the flat coil is disposed spaced apart from the core arrangement; and a heat conducting element at least partially surrounding the pressure pedestal and connecting the stranded wire carrier with the core body in a heat-transmitting manner.

20 . A ground assembly for an inductive charging device for inductively charging a motor vehicle parked on a surface, the ground assembly comprising:
a base plate; a flat coil including a helically wound conductor and a stranded wire carrier; a magnetic flux controlling core arrangement including a plurality of core bodies arranged adjacent to one another; a plurality of supports that each extend between an associated core body of the plurality of core bodies and the base plate such that a lower hollow space is defined between the plurality of core bodies and the base plate; the stranded wire carrier including a plurality of pressure pedestals that each protrude therefrom co-axially to an associated support of the plurality of supports and that each support the stranded wire carrier on an associated core body of the plurality of core bodies such that the flat coil is disposed spaced apart from the core arrangement; a heat conducting element at least partially surrounding the plurality of pressure pedestals and connecting the stranded wire carrier with the plurality of core bodies in a heat-transmitting

Assignees

• Mahle Int Gmbh

Inventors

• Boettigheimer Mike
• Himmer Thomas
• Laemmle Christopher
• Steinbach Martin
• Schroth Holger

Classifications

• H02J50/10

  using inductive coupling · CPC title

• H02J50/70

  involving the reduction of electric, magnetic or electromagnetic leakage fields · CPC title

• Y02T90/12

  Electric charging stations · CPC title

• Y02T10/7072

  Electromobility specific charging systems or methods for batteries, ultracapacitors, supercapacitors or double-layer capacitors · CPC title

• Y02T10/70

  Energy storage systems for electromobility, e.g. batteries · CPC title