Wireless charging magnetic structure

• US 10,131,236 B2
• Filed: 04/17/2015
• Issued: 11/20/2018
• Est. Priority Date: 04/17/2015
• Status: Active Grant

• Current Assignee: Lear Corporation
• Original Assignee: Lear Corporation
• Inventors: Neumann, Aribert, Hein, David A., Bhattacharya, Madhur
• Primary Examiner(s): Grant, Robert
• Application Number:
  US14/689,220
• Publication Number:
  US 20160303981A1
• Time in Patent Office: 1,313 Days
• Field of Search: 320108
• CPC Class Codes: B60L 53/12 Inductive energy transfer
• CPC Class Codes: B60L 53/126 Methods for pairing a vehicle and a charging station, e.g. establishing a one-to-one relation between a wireless power transmitter and a wireless power receiver
• CPC Class Codes: H01F 27/36 Electric or magnetic shields or screens movable for varying inductance H01F21/10
• CPC Class Codes: H01F 27/366 made of ferromagnetic material
• CPC Class Codes: H01F 3/08 made from powder powder coatings on sheets H01F3/02; on strips or ribbons H01F3/04; on wires H01F3/06
• CPC Class Codes: H01F 38/14 Inductive couplings for wireless supply or distribution of electric power using inductive coupling H02J50/10
• CPC Class Codes: Y02T 10/70 Energy storage systems for electromobility, e.g. batteries
• CPC Class Codes: Y02T 10/7072 Electromobility specific charging systems or methods for batteries, ultracapacitors, supercapacitors or double-layer capacitors
• CPC Class Codes: Y02T 90/14 Plug-in electric vehicles

Abstract

In at least one embodiment, an inductive charging coil assembly for a vehicle comprising a first base plate and a second base plate is disclosed. The first base plate includes at least one first coil for transmitting magnetic flux. The second base plate includes at least one second coil having a top side and a bottom side to receive the magnetic flux for charging a vehicle. The at least one second coil defines a window to position at least one ferrite on the top side and on the bottom side of the at least one second coil. The at least one ferrite is arranged to guide the magnetic flux from the bottom side of the at least one second side to the top side of the at least one second side and back to the bottom side of the at least one second side.

Claims

1. An inductive charging coil assembly for a vehicle comprising:

a first base plate including at least one first coil for transmitting magnetic flux; and

a second base plate including at least one second coil having a top side and a bottom side to receive the magnetic flux for charging a vehicle,

wherein the at least one second coil defines a window to position at least one ferrite on the top side and on the bottom side of the at least one second coil, and

wherein the at least one ferrite is arranged to guide the magnetic flux from the bottom side of the at least one second coil to the top side of the at least one second coil and back to the bottom side of the at least one second coil.

2. The assembly of claim 1 wherein the at least one first coil is a primary coil.

3. The assembly of claim 2 wherein the at least one second coil is a secondary coil.

4. The assembly of claim 1 wherein the at least one second coil includes an angled portion that defines the window.

5. The assembly of claim 4 wherein the angled portion receives a joining portion of the at least one ferrite to position the at least one ferrite on the top side and on the bottom side of the at least one second coil.

6. The assembly of claim 4 wherein the angled portion forms an incline relative to remaining portions of the at least one second coil.

7. The assembly of claim 1 wherein the second base plate is positioned on the vehicle for receiving the magnetic flux from the first base plate.

8. The assembly of claim 1 wherein the first base plate is horizontally spaced apart from the second base plate.

9. The assembly of claim 1 wherein an overall size of the first base plate is greater than an overall size of the second base plate to provide for a uniform coupling coefficient between the first base plate and the second base plate.

10. The assembly of claim 1 wherein the at least one ferrite includes a top portion and a bottom portion and wherein the top portion overlaps the bottom portion.

11. An inductive charging coil apparatus for a vehicle comprising:

a vehicle base plate including at least one coil having a top side and a bottom side for receiving magnetic flux from a second base plate to charge a vehicle,

wherein the at least one coil defines a window to receive at least one ferrite to position the at least one ferrite on the top side and on the bottom side of the at least one coil, and

wherein the at least one ferrite is arranged to guide the magnetic flux from the bottom side of the at least one coil to the top side of the at least one coil and back to the bottom side of the at least one coil.

12. The apparatus of claim 11 wherein the at least one coil is a secondary coil for receiving the magnetic flux from a primary coil positioned on the second base plate.

13. The apparatus of claim 11 wherein the at least one coil includes an angled portion that defines the window.

14. The apparatus of claim 13 wherein the angled portion receives a joining portion of the at least one ferrite to position the at least one ferrite on the top side and on the bottom side of the at least one coil.

15. The apparatus of claim 13 wherein the angled portion forms an incline relative to remaining portions of the at least one coil.

16. The apparatus of claim 11 wherein the vehicle base plate is positioned on the vehicle for receiving the magnetic flux from the second base plate.

17. The apparatus of claim 11 wherein the at least one ferrite includes a top portion and a bottom portion and wherein the top portion is positioned directly above the bottom portion.

18. An inductive charging coil assembly for a vehicle comprising:

a first base plate including at least one first coil for transmitting magnetic flux; and

a second base plate including at least one second coil having a top side and a bottom side to receive the magnetic flux for charging a vehicle,

wherein the at least one second coil defines a window including at least one ferrite to direct the magnetic flux from the bottom side of the at least one second coil to the top side of the at least one second coil and back to the bottom side of the at least one second coil.

19. The assembly of claim 18 wherein the at least one second coil receives the at least one ferrite at the window to position the at least one ferrite on the top side and on the bottom side of the at one second coil.

20. The assembly of claim 18 wherein the first base plate is horizontally spaced apart from the second base plate.