EP3207613A1

EP3207613A1 - Coil assembly for inductive energy transmission, inductive energy-transmission device, and method for producing a coil assembly for inductive energy transmission

Info

Publication number: EP3207613A1
Application number: EP15744192.4A
Authority: EP
Inventors: Felix Stewing; Tobias Diekhans
Original assignee: Robert Bosch GmbH
Current assignee: Robert Bosch GmbH
Priority date: 2014-10-16
Filing date: 2015-07-28
Publication date: 2017-08-23
Also published as: US20170243691A1; JP2017534175A; WO2016058719A1; KR20170071488A; DE102014220978A1; CN107078552A

Abstract

The invention relates to a coil assembly (1) for inductive energy transmission, comprising: an electrically non-conductive substrate (2), which has a first side (10) and a second side (11); a plurality of conducting tracks (30), which are arranged on the first side (10) and on the second side (11) of the substrate (2) and which form a coil (50) for inductive energy transmission; a plurality of vias (4) in the substrate (2) for feeding the conducting tracks (30) through the substrate (2); wherein at least two of the plurality of conducting tracks (30) are arranged in a twisted manner in relation to each other in the substrate (2). The invention further relates to an energy transmission device and to a method for producing a coil assembly (1) for inductive energy transmission.

Description

description

title

Coil arrangement for inductive energy transmission, inductive

Energy transmission device and method for producing a

Coil arrangement for inductive energy transmission

The invention relates to a coil arrangement for inductive energy transmission and an inductive energy transmission device. Furthermore, the

The present invention relates to a method of manufacturing a coil arrangement for inductive energy transmission.

State of the art

Electric vehicles powered by an electric motor alone are known. In addition, plug-in hybrid vehicles are known, the drive is effected by a combination of an electric motor and another drive machine. In this case, the electrical energy for driving the electric motor is provided by an electrical energy store, for example a traction battery. After the energy storage is completely or partially discharged, it is necessary to recharge the energy storage. There are various approaches for charging the energy store.

On the one hand, it is possible to electrically connect the electric vehicle to a charging station by means of a suitable charging cable. To do this, the user must establish an electrical connection between the electric vehicle and the charging station. This can be perceived as unpleasant especially in bad weather conditions, such as rain. Due to the very limited electrical range of electric and plug-in hybrid vehicles, this cable connection must be made very often by the user, which is perceived by many users as a major disadvantage of electric vehicles compared to conventional vehicles.

On the other hand, therefore, there are also wireless solutions for transmitting energy from a charging station to an electric vehicle. Here, the energy from the charging station via a magnetic alternating field from a primary coil to a Secondary coil inductively transmitted in the electric vehicle and supplied to the traction battery in the vehicle.

To form the primary coil, sometimes a high-frequency strand (also HF strand) is used, which consists of a larger number of fine, mutually insulated wires, which are intertwined in such a way that statistically each individual wire occupies as many places as possible in the total cross section of the strand.

DE 10 2013 010 695 A1 describes a primary winding arrangement,

which has a winding arrangement with a winding wire. In an advantageous embodiment, an HF strand is used as the winding wire, wherein the strand is designed as a bundle of mutually electrically insulated individual wires.

Disclosure of the invention

The invention provides a coil arrangement for inductive energy transmission with the features of claim 1, and an inductive

Energy transmission device with the features of claim 9, and a

Method for producing a coil arrangement with the features of claim 10.

Accordingly, it is provided:

A coil assembly for inductive power transmission, comprising an electrically non-conductive substrate having a first side and a second side; with a plurality of conductor tracks, which are arranged on the first side and on the second side of the substrate, and which a coil for inductive

Form energy transfer; with a plurality of vias in the

Substrate for the passage of the conductor tracks through the substrate; wherein at least two of the plurality of conductor tracks are arranged in the substrate stranded to each other.

Furthermore, an inductive energy transmission device with at least one coil arrangement according to the invention is provided. Furthermore, a method for producing a coil arrangement for inductive energy transmission is provided with the following method steps:

Providing an electrically non-conductive substrate having a first side and a second side; Forming a plurality of conductive traces on the first side and on the second side of the substrate to form an inductive energy transfer coil, wherein at least two of the plurality of conductive traces are formed in the substrate stranded with each other.

Preferred developments are the subject of the respective subclaims. Advantages of the invention

The idea on which the present invention is based, instead of a wound HF strand, is to use a substrate with interconnects formed thereon and mutually stranded as a coil for inductive energy transmission.

By using a substrate for the realization of the strand, several advantages can be eliminated at the same time and more functions can be covered than the pure generation of the alternating magnetic field. Furthermore, there is the simple possibility of partial reactive power compensation of individual windings, whereby the maximum occurring resonance voltage can be limited.

Another advantage of the coil arrangement presented here is the very simple production with known technologies. For example, the coil arrangement z. B. as a multilayer board (PCB) or z. B. be made as LTCC board (ceramic). This z. B. simply manufactured substrate segments in conventional technology, assembled and then assembled or it is, for. B. at smaller

Coil systems, the entire coil system made on a single substrate.

By forming an RF strand of stranded conductor tracks on a substrate, the electromagnetic properties of the coil can be set very accurately and also be precalculated, z. B. it is now possible by a stranding with low filling factor, the mutual influence of the individual and other countries

To reduce individual turns compared to a conventional stranded wire. In this context, stranded means that at least two conductor tracks run alternately over the feedthroughs from the first side of the substrate to the second side of the substrate and again to the first side of the substrate. The conductor tracks are wound in this way against each other and helically wound around each other.

The inductive energy transfer coil formed by the conductor tracks can be arranged on the substrate in various ways. For example, the coil formed from the conductor tracks may be a honeycomb coil, a basket bottom coil, a cross-wound coil or a coil wound in another way. In this way, the coil can be well adapted to the respective requirements.

The tracks exchange their place either in their entire course and / or at certain points. The stranding factor is between 1.001 and 2.0, in particular between 1.02 and 1.04.

Of course, the stranding is not limited to only two conductor tracks, but it is possible that any number of conductor tracks are stranded to each other. For example, three tracks, four

Conductor tracks, five interconnects, ten interconnects or all interconnects stranded to each other.

By dividing into individual interconnects, the overall fill factor becomes lower, however, a low fill factor can be exploited, for example, by clever magnetic design. Proximity and / or skin effects to minimize. According to a preferred development, the substrate is formed from a plurality of substrate segments. For example, the substrate may be formed of multiple substrate segments that have been fabricated, populated, and then assembled using known technologies. In this way, the coil arrangement can be adapted in a very simple manner to the respective field of application. Furthermore, costs can be saved by this training, since existing manufacturing equipment can be used for the production of the coil assembly.

According to a further preferred development, the substrate segments are formed symmetrical in shape. By this design of the coil assembly can Further costs can be saved since the formation of form-symmetrical substrate segments brings manufacturing advantages, in particular for large quantities.

According to a further preferred development, the substrate is formed from a plurality of annular segment-shaped substrate segments. For example, that is

Substrate formed of 2, 3, 4, 5, 6, 7, 8 or more individual substrate segments. The substrate segments may then form a circle, or other shape, e.g. As a quadrangle, and thus form a single substrate. By this training, the manufacturing costs and the total cost of production can be reduced, since the production of similar trained

Substrate segments automated and can be done in large quantities.

According to a further preferred embodiment, the substrate or a

Substrate segment on a conductor track portion, which is formed for the variable interconnection of the conductor tracks. For example, a substrate segment has one

Track section on which two, three or more tracks or

Track sections electrically coupled together. As a result of this design, the number of turns and / or the winding cross-section of the coil can be adapted in a simple manner to the respective application without having to change all the substrate segments or the entire substrate.

According to a further preferred development, the conductor track section for the variable connection has active switches for adapting the number of turns and / or the winding cross section of the coil. The switches may be formed, for example, as a semiconductor switch or as a relay, and be controlled via a control device. In this way, even during operation of the coil, the number of turns and / or the winding cross section of the coil can be adjusted.

According to a preferred development, capacitors for interconnecting the conductor tracks of the substrate segments are arranged between adjacent substrate segments. For example, ceramic capacitors can be used to interconnect the individual substrate segments. Ceramic capacitors can be easily produced in the desired shape due to the easy moldability of the ceramic matrix. Furthermore, ceramic capacitors are difficult to ignite. Furthermore, ceramic capacitors in the form of SMD Ceramic multilayer capacitors (MLCC) are technically and inexpensively manufactured as a surface-mountable components. However, the capacitors can also z. B. be designed as film capacitors.

According to a further preferred development, the substrate has several

Substrate layers, wherein the conductor tracks on both sides of the individual

Substrate layers are formed. By forming the substrate with a plurality of substrate layers, a multilayer board can be formed, which has a larger number of conductor tracks and thus coil windings and / or winding cross-section. For example, a substrate 3, 4, 5, 6, 7, 8, 9, 10, 11, 12 or any number of substrate layers. In this way, the coil arrangement can be easily adapted to the respective field of application.

According to a further preferred development, capacitors are on the

Substrate arranged, which are designed for reactive power compensation of the coil. By forming the coil on a substrate, several

Capacitors are used, since this training is enough space available. Furthermore, by this design, the waste heat of the capacitors can be dissipated via the substrate in a particularly effective manner. Furthermore, a partial compensation possible, whereby the maximum occurring resonance voltages can be reduced with advantages in terms

electromagnetic compatibility and insulation requirements.

Preferably, the reactive power compensation is distributed to at least two capacitors, which are arranged on two different conductor tracks and / or conductor track sections and / or substrate segments. In this way it becomes possible to carry out the reactive power compensation in sections and / or in segments. Distributed reactive power compensation offers advantages with regard to the electromagnetic compatibility (EMC) and the insulation requirements, since the maximum occurring resonance voltage can also be reduced in sections.

According to a further preferred embodiment, the conductor tracks are formed tapered in the region of the bushings. In this way, a higher packing density of the conductor tracks in the substrate can be achieved. Furthermore, the degree of stranding of the individual conductor tracks can be increased in this way. Brief description of the drawings

Further features and advantages of the present invention will be explained below with reference to embodiments with reference to the figures.

Show it:

Fig. 1 is a schematic plan view of a coil assembly according to a

Embodiment of the present invention;

FIG. 2 is a schematic plan view of a coil assembly according to another embodiment of the present invention; FIG.

3 is a schematic sectional view of a coil assembly according to another embodiment of the present invention;

4 is a schematic sectional view of a coil assembly according to another embodiment of the present invention;

5 is a schematic sectional view of a coil assembly according to another embodiment of the present invention;

6 is a schematic sectional view of a coil assembly according to another embodiment of the present invention;

FIG. 7 is a schematic plan view of a coil assembly according to another embodiment of the present invention; FIG. and a schematic plan view of a section of a

Coil assembly according to another embodiment of the present invention;

9 is a schematic plan view of a coil assembly according to another embodiment of the present invention; a schematic representation of stranded conductor tracks according to another embodiment of the present invention; a schematic representation of stranded conductor tracks according to another embodiment of the present invention; a schematic representation of a power transmission device according to an embodiment of the present invention; and a schematic flow diagram of a method for producing a coil arrangement for inductive energy transmission.

In the figures, like reference numerals designate the same or functionally

Elements.

Fig. 1 shows a schematic plan view of a coil assembly 1 according to an embodiment of the present invention. The inductive energy transfer coil assembly 1 includes an electrically non-conductive substrate 2 having a first side 10 and a second side 11 (not shown). On the first side 10 and on the second side 11 of the substrate 2, a plurality of interconnects 30 are arranged, which form a coil 50 for inductive energy transfer. Furthermore, the coil arrangement 1 has a multiplicity of plated-through holes 4, which are provided in the substrate 2 for the passage of the conductor tracks 30 through the substrate 2. Of the plurality of interconnects 30 in the substrate 2, at least two interconnects 30 are arranged in a stranded relationship to one another. Further, on the first side of the substrate 2, a conductor track portion 31 is formed, which for

Connection of the individual coil windings is formed.

Fig. 2 shows a schematic plan view of a coil assembly 1 according to another embodiment of the present invention. In the illustrated

Embodiment, the substrate 2 of three substrate segments 20, 21, and 22 is formed. In particular, the individual substrate segments 20, 21 and 22 are formed symmetrical in shape, whereby these in a simple manner in large numbers can be produced. In the embodiment shown in Fig. 2, the substrate segments 20, 21, and 22 are formed in a circular segment. However, the substrate segments 20, 21, and 22 may also be formed in a different shape. For example, the substrate segments 20, 21, and 22 may also be square, rectangular or polygonal. Furthermore, capacitors 8 are arranged between the substrate segments, which serve for reactive power compensation and for interconnecting the substrate segments. On the substrate segment 22, a conductor track section 31 is also formed, which serves the interconnection of the individual conductor tracks 30. In the illustrated embodiment, the

Track section 31 for variable interconnection active switch 35 for adjusting the number of turns and / or the winding cross-section of the coil. The switches 35 may be formed, for example, as a semiconductor switch and / or as a relay, and (not shown) via a control device to be controlled. In this way, even during operation of the coil, the number of turns and / or the winding cross section of the coil can be adjusted.

3 shows a schematic sectional view of a coil arrangement 1 according to a further embodiment of the present invention. The substrate 2 has a first side 10 and a second side 11. On the first side 10 and on the second side 11 conductor tracks 30 are arranged, which are formed by the conductor track sections 33 and 34.

As can be seen, the conductor track sections 33 and 34 are arranged in a stranded relation to one another. This means that the conductor track sections 33 and 34 run alternately over the feedthroughs 4 from the first side 10 to the second side 11 and again to the first side 10. In this way, the interconnects 30 are formed stranded to each other.

4 shows a schematic sectional view of a coil arrangement 1 according to a further embodiment of the present invention. In this embodiment, the substrate 2 is formed of two substrate layers 25 and 26. On the

Substrate layers 25 and 26 are conductor track sections 33, 34 and 35 are formed. Also, the conductor track portions 33, 34 and 35 are in the substrate 2 by means of

Bushings 4 arranged stranded to each other. Of course, it is possible that the coil arrangement 1 has more than two substrate layers 25 and 26. For example, the coil arrangement can also be 3, 4, 5, 6 or any number

Substrate layers with each other stranded interconnects 30 have.

Fig. 5 shows a schematic sectional view of a coil assembly 1 according to another embodiment of the present invention. In this embodiment, capacitors 8 are arranged on the substrate 2 between the interconnects 30. For example, the capacitors 8 are provided for reactive power compensation of the coil 50. Due to the capacitors 8, the coil assembly 1 can be optimally adapted to the particular field of application and the respective boundary conditions in a simple manner. By arranging the capacitors 8 on the substrate 2, the waste heat of the capacitors 8 can be dissipated via the substrate 2 in a particularly effective manner.

Fig. 6 shows a schematic sectional view of a coil assembly 1 according to another embodiment of the present invention. In this embodiment, the substrate 2 is formed of two substrate segments 20 and 21. Between the substrate segments 20 and 21 are capacitors 8 for interconnecting the

Printed conductors 30 are provided. In this way, the capacitors 8 can be used for reactive power compensation and for interconnecting the substrate segments 20 and 21.

7 shows a schematic representation of a further embodiment of a coil arrangement 1. The conductor tracks 30 shown in FIG. 7 once again consist of a plurality of interconnects 30 stranded using multilayer technology. This has the advantage that the stranding quality is precisely set and predicted can, what is not possible with a conventional stranded wire. Another advantage is the possibility of having a "very loose" stranding

to realize increased distance between the conductors 30. Since a high packing density is not required here, the proximity losses can be reduced since the interconnects do not lie close together and have a sufficient distance from one another. Another advantage is the better coolability of the individual coil winding, since there is no air in the coil 50, and a flat cooling interface to the capacitors 8 and the interconnects 30th

is available. Furthermore, by this training on a coil 50th

surrounding encapsulant be omitted. It is also possible by the formation of the coil 50 on the substrate 2, virtually any number of capacitors 8 to place the

Reactive power compensation in the inductive energy transfer are needed. Instead of the usual today film capacitors can be achieved by such a configuration z. B. S MD ceramic capacitors for sections

Use reactive power compensation. Also in the cooling of the capacitors 8, there are advantages if they can be distributed over a larger area. Further advantages are in terms of electromagnetic compatibility (EMC) and insulation requirements by a distributed reactive power compensation, since the maximum occurring resonance voltage can be reduced. The coil arrangement 1 for inductive energy transmission shown in FIG. 7 is a series-compensated coil 50. Of course, the production technique shown here is also applicable to parallel-compensated coils or any other type of compensation. The coil arrangement 1 shown in FIG. 7 is also formed from a plurality of segment segments 20, 21, 22, and 23, which are in the form of segments. On the substrate segment 23, a conductor track portion 31 is also formed, which serves the interconnection of the individual conductor tracks 30.

8 shows a schematic plan view of a detail of a coil arrangement 1 according to a further embodiment of the present invention. In this

Embodiment, the substrate 2 is formed of a plurality of substrate segments, wherein in Fig. 8, a substrate segment 25 is shown, which has a

Track section 31 which is designed for interconnecting the conductor tracks 30. By means of the conductor track section 31, it is possible to realize with the same substrate 2 different numbers of turns and / or conductor cross-sections. The track portion 31 is formed in this embodiment, two adjacent

Conductors 30 to connect electrically with each other. With this design, the inductance of the coil 50 can be easily adapted to the particular application while optimally distributing the power and utilizing the entire copper to conduct electricity.

9 shows a schematic plan view of a coil assembly 1 according to another embodiment of the present invention. In this embodiment, the substrate 2 is formed of two substrate segments 20 and 21 having a rectangular shape. The conductor tracks 30 do not run in a circular manner here, but rectangular. On the substrate segment 20 is also a Track section 31 is formed, which for interconnecting the individual

Tracks 30 is used. The interconnection may e.g. in a simple way by the

Placement of the resonant capacitors made at this point.

10 shows a schematic representation of stranded conductor tracks 30 according to a further embodiment of the present invention. FIG. 10 shows four interconnects 301, 302, 303, and 304, which extend on the first side of the substrate. Furthermore, printed conductors 301 ', 302', 303 'and 304' are shown which run on the second side of the substrate. The tracks 301, 302, 303, and 304 are electrically connected to the tracks 301 ', 302', 303 ', and 304', respectively. The conductor tracks 301, 302, 303, and 304 each extend in steps from the left to the right in descending order. The conductor tracks 301 ', 302', 303 ', and 304' each extend in a stepped manner from left to right in ascending order. The conductor tracks 301, 302, 303 and 304 extend from the first side of the substrate to the second side of the substrate via feedthroughs 4

Tracks 301, 302, 303, 304, 301 ', 302', 303 ', and 304' are stranded with each other, which can reduce the losses at higher frequencies caused by the effect of the current displacement (skin effect).

11 shows a schematic representation of stranded conductor tracks 30 according to a further embodiment of the present invention. In this

Embodiment, the stranding of interconnects 300 in three levels A, B, C is shown. For example, the three planes A, B, C are formed in a two-layered substrate. On the first level A are three printed conductors 301, 302 and 303. The three interconnects 301, 302, and 303 are guided by means of feedthroughs 4 to the plane B, wherein in the plane B, a conductor track section 31 is formed, which the interconnection of the interconnects 30 serves. Furthermore, also on the level B

Conductor tracks 301 ', 302', 303 'and formed on the level C tracks 301 ", 302", 303 ", which are connected to the tracks 301, 302, and 303. In the area Bl, the tracks of the planes A and C are braid-like In the area B2, the interconnects 30 of the levels B and C are stranded like a plait to each other, wherein in the plane A a conductor track portion 31 is formed, which the interconnection and / or the stranded arrangement of the interconnects 30. The interconnect section 31 for interconnecting the interconnects 30 can change the level at regular intervals. Of course, this type of stranding can also be performed at more than three levels.

FIG. 12 shows a schematic representation of a power transmission device 100 according to an embodiment of the present invention. The

Energy transmission device 100 has a coil arrangement 1 according to the invention. The coil assembly 1 is configured to generate an alternating magnetic field and to inductively transmit energy to a receiver device 200. The receiver device 200 may, for example, a traction battery of

Be electric vehicle.

FIG. 13 shows a schematic flow diagram of a method for producing a coil arrangement for inductive energy transmission. In method step S1, an electrically non-conductive substrate having a first side and a second side is provided. In method step S2, a multiplicity of conductor tracks are formed on the first side and on the second side of the substrate for forming an inductive energy transfer coil, wherein at least two of the plurality of conductor tracks are formed in the substrate in a stranded form. Further

Process steps may be upstream, interposed and / or downstream, in particular for the production of multilayer substrates

The inductive energy transfer device and the invention

Coil arrangement can also be used, for example, for contactless charging of power tools, e-bikes, household appliances and consumer electronic devices.

Also, the type of stranding and the type of winding can be adapted to the respective

Application area and the respective boundary conditions are adjusted.

Claims

claims

A coil assembly (1) for inductive power transmission comprising an electrically non-conductive substrate (2) having a first side (10) and a second side (11); a plurality of conductive traces (30) disposed on the first side (10) and on the second side (11) of the substrate (2) and forming a coil (50) for inductive power transmission; with a plurality of vias (4) in the substrate (2) for

Passing the conductor tracks (30) through the substrate (2); wherein at least two of the plurality of conductor tracks (30) in the substrate (2) are arranged in a stranded relation to one another.

2. coil arrangement (1) according to claim 1,

wherein the substrate (2) is formed of a plurality of substrate segments (20; 21; 22; 24; 25).

3. coil arrangement (1) according to claim 1 or 2,

wherein the substrate segments (20; 21; 22; 24; 25) are circular segment-shaped.

4. coil arrangement (1) according to one of claims 1 to 3,

wherein the substrate (2) or a substrate segment (25) has a conductor track section (31), which is formed for the variable interconnection of the conductor tracks (30).

5. coil arrangement (1) according to claim 4,

wherein the track section (31) for variable connection comprises active switches (35) for adjusting the number of turns and / or the winding cross-section of the coil (50).

6. coil arrangement (1) according to one of claims 2 to 5,

wherein between at least two adjacent substrate segments (20; 21) capacitors (8) for interconnecting the conductor tracks (30) of the substrate segments (20; 21) are arranged.

7. coil arrangement (1) according to one of the preceding claims,

wherein the substrate (2) comprises a plurality of substrate layers (25; 26), and the

Conductor tracks (30) on both sides of the individual substrate layers (25; 26) are formed.

8. coil arrangement (1) according to one of the preceding claims,

wherein capacitors (8) are arranged on the substrate (2), which are designed for reactive power compensation of the coil (50).

9. Inductive energy transmission device (100),

with at least one coil arrangement (1) according to one of the preceding

Claims.

10. A method for producing a coil assembly (1) for inductive

Energy transfer according to one of the preceding claims with the following methods:

Providing an electrically non-conductive substrate (2) having a first side (10) and a second side (11);

Forming a plurality of conductor tracks (30) on the first side (10) and on the second side (11) of the substrate (2) to form a coil (50) for inductive power transmission, wherein at least two of the plurality of conductor tracks (30) in the substrate (2) are formed stranded to each other.