Low inductance pad winding using a matched winding of multiple spirals

• US 10,148,117 B2
• Filed: 06/28/2016
• Issued: 12/04/2018
• Est. Priority Date: 06/29/2015
• Status: Active Grant

• Current Assignee: Wireless Advanced Vehicle Electrification, Inc.
• Original Assignee: Wireless Advanced Vehicle Electrification, Inc.
• Inventors: Lethellier, Patrice, Wu, Hunter
• Primary Examiner(s): Isla, Richard
• Assistant Examiner(s): Dibenedetto, Michael
• Application Number:
  US15/195,836
• Publication Number:
  US 20160380469A1
• Time in Patent Office: 889 Days
• Field of Search: 320108, 307104
• CPC Class Codes: H01F 38/14 Inductive couplings for wireless supply or distribution of electric power using inductive coupling H02J50/10
• CPC Class Codes: H02J 50/10 using inductive coupling
• CPC Class Codes: H02J 50/70 involving the reduction of electric, magnetic or electromagnetic leakage fields

Abstract

An apparatus for wireless power charging includes a first charging coil with a first conductor arranged in a winding pattern with a first winding around a center point and each successive winding of the first charging coil is further away from the center point than the first winding and any previous windings. A second charging coil includes a second conductor wound with respect to the first charging coil where each coil of the second charging coil is arranged between each winding of the first charging coil. The first charging coil and second charging coil are connected in parallel. A ferrite structure is positioned adjacent to the first charging coil and the second charging coil.

Claims

1. An apparatus comprising:

a first charging coil comprising a first conductor arranged in a winding pattern with a first winding around a center point and each successive winding of the first charging coil is further away from the center point than the first winding and any previous windings;

a second charging coil comprising a second conductor wound with respect to the first charging coil where each coil of the second charging coil is arranged between each winding of the first charging coil, wherein the first charging coil and second charging coil are connected in parallel; and

a ferrite structure positioned adjacent to the first charging coil and the second charging coil,

wherein the first charging coil and the second charging coil are wound in a same direction, and

wherein each charging coil comprises an inner starting point located closer to the center point than each successive winding of the charging coil, and wherein the inner starting point for each charging coil is a same radius from the center point and the inner starting point of the first charging coil is separated from the inner starting point of the second charging coil in a direction radially around the center point.

2. The apparatus of claim 1, wherein the inner starting point of the first charging coil is spaced around a starting point circle equidistant from the inner starting point for of the second charging coil, the starting point circle centered about the center point.

3. The apparatus of claim 1, further comprising an additional charging coil, the additional charging coil comprising an additional conductor wound with respect to the first charging coil, second charging coil, and any other additional charging coils where each winding of an additional coil is arranged between each winding of the first charging coil and the second charging coil and any other additional charging coils.

4. The apparatus of claim 3, wherein each charging coil comprises an inner starting point, the inner starting point comprising a location where a first winding begins, the first winding closer to the center point than additional windings of the charging coil, wherein the inner starting point for each charging coil is a same radius from the center point, and wherein the inner starting point for each charging coil is spaced around a starting point circle equidistant from the inner starting point for other charging coils, the starting point circle centered about the center point.

5. The apparatus of claim 1, wherein each charging coil is wound so that at a particular radial from the center point each successive winding around an innermost winding is further from the previous winding and positioned substantially planar with respect to a line perpendicular to the center point.

6. The apparatus of claim 5, wherein each winding of each charging coil is arranged to be substantially planar.

7. The apparatus of claim 5, wherein each charging coil is arranged in an Archimedean spiral.

8. The apparatus of claim 5, wherein each charging coil is arranged in an irregular spiral, wherein the irregular spiral comprises portions of a winding that vary in radius with respect to the center point other than variation between a starting point and an ending point of a winding to accommodate beginning of a next winding of the charging coil and to allow for windings of one or more additional charging coils.

9. The apparatus of claim 8, wherein each charging coil is arranged in one or more of substantially a square shape and substantially a D-shape.

10. The apparatus of claim 1, wherein at least a portion of a surface of the ferrite structure is planar and parallel to at least a portion of the first charging coil and second charging coil that are adjacent.

11. The apparatus of claim 10, wherein a side of the ferrite structure adjacent to the first charging coil and second charging coil is planar and the first charging coil and second charging coil are planar and are parallel to the side of the ferrite structure.

12. The apparatus of claim 10, wherein charging coils of the apparatus comprise a first portion positioned planar in a first plane and positioned adjacent to a section of the ferrite structure and the charging coils comprise a second portion positioned planar in a second plane and positioned adjacent to a planar section of the ferrite structure, wherein the first plane and second plane are different planes.

13. The apparatus of claim 12, wherein the charging coils comprise a first set of charging coils and further comprising a second set of charging coils positioned adjacent to the first set of charging coils, wherein a portion of each of the first and second sets of charging coils are positioned adjacent and are positioned substantially in the first plane and portions of the first set of charging coils and the second set of charging coils positioned away from the adjacent sections of the first and second sets of charging coils are positioned substantially in the second plane.

14. The apparatus of claim 1, wherein the conductor of each charging coil comprises a first lead and a second lead, the first and second leads comprise portions of the conductor of each charging coil extending from windings of the charging coils, wherein at least a portion of the first and second leads of each of the charging coils are grouped together in a pattern that one of

adds inductance in addition to inductance of a winding portion of the charging coils;

and

subtracts inductance from the inductance of a winding portion of the charging coils, wherein the pattern is chosen to adjust a total amount of inductance of the charging coils.

15. The apparatus of claim 1, wherein the conductor of each charging coil comprises a first lead and a second lead, the first and second leads comprise portions of the conductor of each charging coil extending from windings of the charging coils, wherein ends of the first leads are connected and ends of the second leads are connected such that the charging coils are connected in parallel.

16. The apparatus of claim 1, wherein the ferrite structure comprises a plurality of ferrite bars arranged in a radial pattern extending away from the center point.

20. The apparatus of claim 2, wherein the first charging coil and the second charging coil each comprise an outer ending point, wherein the outer ending point of the first charging coil and the outer ending point of the second charging coil are spaced around an ending point circle centered about the center point and wherein the outer ending point of the first charging coil is equidistant from the outer ending point of the second charging coil.

17. An apparatus comprising:

a first charging coil comprising a conductor arranged in a winding pattern with a first winding around a center point and each successive winding of the first charging coil is further away from the center point than the first winding and any previous windings;

one or more additional charging coils, each charging coil comprising a conductor wound with respect to the first charging coil where each coil of an additional charging coil is arranged between each winding of the first charging coil, wherein the first charging coil and additional charging coils are connected in parallel,

wherein the first charging coil and the second charging coil are wound in a same direction, and

wherein each charging coil comprises an inner starting point located closer to the center point than each successive winding of the charging coil,

wherein the inner starting point for each charging coil is positioned a same radius from the center point,

wherein the inner starting point for each charging coil is spaced around a starting point circle equidistant from the inner starting point for other charging coils, the starting point circle centered about the center point,

wherein the first charging coil and the one or more additional charging coils are connected in parallel,

wherein the first charging coil and the one or more additional charging coils are substantially planar; and

a ferrite structure positioned adjacent to the first charging coil and the one or more additional charging coils, at least one side of the ferrite structure is planar and is positioned adjacent to the first charging coil and the one or more additional charging coils.

18. A system comprising:

a first charging coil comprising a first conductor arranged in a winding pattern with a first winding around a center point and each successive winding of the first charging coil is further away from the center point than the first winding and any previous windings;

one or more additional charging coils, each charging coil comprising a conductor wound with respect to the first charging coil where each coil of an additional charging coil is arranged between each winding of the first charging coil, wherein the first charging coil and additional charging coils are connected in parallel;

wherein the first charging coil and the second charging coil are wound in a same direction, and

wherein each charging coil comprises an inner starting point located closer to the center point than each successive winding of the charging coil, and wherein the inner starting point for each charging coil is a same radius from the center point and the inner starting point of the first charging coil is separated from the inner starting point of the second charging coil in a direction radially around the center point;

a ferrite structure positioned adjacent to the first charging coil and the one or more additional charging coils, the charging coils and ferrite structure comprising a charging pad; and

one of

a resonant converter connected to the charging pad and providing power to the charging pad; and

a secondary circuit that receives power from the charging pad and conditions the power for a load.

19. The system of claim 18, wherein the charging pad comprises a primary charging pad and is connected to the resonant converter and further comprising:

a second charging pad connected to the secondary circuit; and

one or more of an energy storage device and a motor, the energy storage device and motor receiving power from the secondary circuit.