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EP-4739536-A1 - WIRELESS CHARGING MODULE COMPRISING A COOLING CHANNEL

EP4739536A1EP 4739536 A1EP4739536 A1EP 4739536A1EP-4739536-A1

Abstract

The invention relates to a wireless charging module which is used to exchange electrical energy with a vehicle. Said charging module comprises a magnetic assembly (6) and an electronic assembly (7) and a cooling system for dissipating heat generated by the two assemblies (6, 7) during their operation. The cooling system has a cooling channel structure with at least one coolant channel (90) and with at least two flow-guiding elements (45) that extend transversely to a flow direction. The width of the flow-guiding elements (45) is greater than the distance between the flow-guiding elements (45).

Inventors

  • PFÄTTISCH, Veit
  • Zürcher, Nadir

Assignees

  • BRUSA Elektronik AG

Dates

Publication Date
20260513
Application Date
20240701

Claims (14)

  1. 1. Wireless charging module for charging a battery (5) of a vehicle (2) and/or for feeding a consumer of the vehicle (2) and/or for delivering energy from the battery (5) of the vehicle (2) and/or for delivering energy from an energy source of the vehicle (2), with • a first, in particular magnetic, assembly (6) for receiving an oscillating electromagnetic field and converting it into an alternating electrical current; • a second, in particular electronic, assembly (7) for receiving the alternating electrical current and converting it into an electrical current for charging the battery (5) or for supplying the consumer, • a cooling system (8) for dissipating heat generated by the two assemblies (6, 7) during their operation by means of a coolant flow (80); • wherein the cooling system (8) has a cooling channel structure (9) with at least one coolant channel (90) and with at least two flow guide elements (45) extending transversely to a flow direction, • wherein a width of the flow guide elements (45) is greater than a distance between the flow guide elements (45).
  2. 2. Wireless charging module (4) according to claim 1, wherein the width of the flow guide elements (45) is at least one and a half times, in particular at least twice, in particular at least three times larger than a distance between the flow guide elements (45).
  3. 3. Wireless charging module (4) according to one of the preceding claims, wherein the flow guide elements (45) are arranged at their flow-facing side facing side (46) have an at least approximately semicircular cross-section, and in particular on their side facing away from the flow (47) also have an at least approximately semicircular cross-section.
  4. 4. Wireless charging module (4) according to claim 3, wherein the flow guide elements (45) have a circular cross-section.
  5. 5. Wireless charging module (4) according to claim 3, wherein the flow guide elements (45) have an oval cross-section or an egg-shaped cross-section.
  6. 6. Wireless charging module (4) according to claim 3, wherein the flow guide elements (45) are arranged in a curved section of the coolant channel (90), and a length of the flow guide elements (45) in the flow direction is greater than a width of the flow guide elements (45) normal to the flow direction, and in an intermediate region between the flow guide elements which extends in the flow direction, the distance between the flow guide elements (45) at different locations in the intermediate region is substantially the same.
  7. 7. Wireless charging module (4) according to claim 5 or 6, wherein a length of the flow guide elements (45) in the flow direction is less than two and a half times a width of the flow guide elements (45) normal to the flow direction, and in particular at least approximately equal to twice.
  8. 8. Wireless charging module (4) according to one of the preceding claims, wherein the flow guide elements (45) extend from a first inner wall (94) of the coolant channel (90) up to or at least approximately up to an opposite second inner wall (95).
  9. 9. Wireless charging module (4) according to one of the preceding claims, wherein the flow guide elements (45) are made of a metal.
  10. 10. Wireless charging module (4) according to claim 9, wherein the flow guide elements (45) are formed integrally on an inner wall of the coolant channel (90) made of metal.
  11. 11. Wireless charging module (4) according to claim 9, wherein the flow guide elements (45) are inserted into an inner wall of the coolant channel (90) formed from a non-metallic material and are guided to a heat transfer body which is arranged to absorb heat from an assembly (6, 7) which generates heat during operation and is to be cooled.
  12. 12. Wireless charging module (4) according to one of the preceding claims, wherein the coolant channel (90) has at least one cooling section (91, 92), and the flow guide elements (45) are arranged in this cooling section (91, 92) for dissipating heat from an assembly (6, 7) that generates heat during operation and is to be cooled, in particular from at least one of the magnetic assembly (6) and the electronic assembly (7).
  13. 13. Wireless charging module (4) according to one of the preceding claims, wherein the coolant channel has a substantially rectangular cross-section, the extent along the first direction of which is hereinafter referred to as height and the extent along the second direction of which is hereinafter referred to as width, the width being at least three times the height.
  14. 14. Wireless charging module (4) according to one of the preceding claims, wherein the cooling channel structure is arranged between at least a first part (41) and a second part (42) and one or more channels of the cooling channel structure (9) are formed by recesses in the first part (41) and/or in the second part (42), in particular wherein the first part (41) and/or the second part (42) are plate-like or flat.

Description

WIRELESS CHARGING MODULE WITH COOLING CHANNEL The present invention relates to a wireless charging module for charging a battery or for feeding a consumer of a vehicle. Batteries of electric vehicles can be charged with alternating current (AC) or direct current (DC). Typical AC chargers can provide a charging power of up to 22 kW. AC charging systems can be divided into wired charging systems and wireless charging systems, with wireless charging systems mainly being designed as inductive charging systems (ICS). Wired AC chargers are usually integrated into electric vehicles and are also referred to as on-board chargers. An ICS usually consists of two separate modules, often referred to as a ground pad module (GPM) and a car pad module (CPM). The GPM is installed outside the electric vehicle, while the CPM is attached inside the electric vehicle, usually on the underside of the vehicle. The electromagnetic interaction between the GPM and the CPM enables the transfer of energy from the GPM to the CPM and vice versa, and the CPM is in turn used to charge an electric vehicle battery. Wireless Charging systems are often more convenient for the user as no manual intervention is usually required to start charging the battery other than parking the vehicle over the GPM. The wireless charging module according to the invention can be used in particular for charging a high-voltage battery or for storing a consumer of a vehicle. In this case, it can be referred to as a car pad module (CPM). This can receive an oscillating magnetic field from an external transmitter, which can be referred to as a ground pad module (GPM). The CPM converts the oscillating electromagnetic, predominantly magnetic field into an alternating current, which is converted (typically rectified) and thereby becomes a charging current (typically direct current) that is used to charge the battery or to power the consumer. The wireless charging module can also be called a power conversion assembly. It is used to convert the electromagnetic power of an oscillating electromagnetic field into electrical power of an electric current or an available electric current for charging an electrical storage or for powering an electrical load. Regarding cooling, it is important to understand that a CPM can have two areas of heat generation: an electronic assembly (power electronics), which generates a lot of heat but is concentrated in certain places on the device, where it has a relatively high density of heat-generating elements, and a magnetic assembly (coil and ferrite), which generates less heat and is relatively spatially distributed, i.e. with a low density of heat-generating elements. It is an object of the invention to provide a wireless charging module of the type mentioned at the outset, which has an improved heat transfer from heat-generating elements to a cooling medium for cooling the charging module. This object is achieved by a wireless charging module having the features of patent claim 1. The wireless charging module is used to charge a battery of a vehicle and/or to power a consumer of the vehicle and/or to deliver energy from the battery of the vehicle and/or to deliver energy from an energy source of the vehicle. It comprises: • a first, in particular magnetic, assembly for receiving an oscillating electromagnetic field and converting it into an alternating electrical current; • a second, in particular electronic, assembly for receiving the alternating electrical current and converting it into an electrical current for charging the traction battery, and • a cooling system for dissipating heat generated by the two assemblies during their operation by means of a coolant flow. The cooling system has a cooling channel structure with at least one coolant channel and with at least two flow guide elements extending transversely to a flow direction, • wherein a width of the flow guiding elements is greater than a distance between the flow guiding elements. This relationship between the width of the flow guide elements and the distances between the flow guide elements leads to an acceleration of the coolant flow in the spaces between the flow guide elements, and this in turn leads to a turbulent flow. This turbulence takes place in the area between the flow guide elements and increases the Heat transfer between the coolant flow and the flow guide elements. The statement that a width of the flow guide elements is greater than a distance between the flow guide elements can also be formulated as follows: viewed in a plane normal to the flow direction, the flow guide elements each extend along a first direction, and in a second direction that is normal to the first direction, a width of the flow guide elements is greater than a distance between the flow guide elements. The distance is equal to a width of a passage between the flow guide elements. In embodiments, viewed in the plane normal to the flow direction, a width of the flow guide elements in the