Bobbin structure and transmitter coil for wireless charging mats

• US 10,622,820 B2
• Filed: 09/08/2017
• Issued: 04/14/2020
• Est. Priority Date: 09/23/2016
• Status: Active Grant

• Current Assignee: Apple Inc.
• Original Assignee: Apple Inc.
• Inventors: Jol, Eric S., Graham, Christopher S., Karanikos, Demetrios B.
• Primary Examiner(s): Williams, Arun C
• Application Number:
  US15/700,038
• Publication Number:
  US 20180090991A1
• Time in Patent Office: 949 Days
• CPC Class Codes: H01F 27/288 Shielding
• CPC Class Codes: H01F 27/325 Coil bobbins formers for coils in general H01F5/02
• 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 50/60 responsive to the presence of foreign objects, e.g. detection of living beings
• CPC Class Codes: H02J 50/70 involving the reduction of electric, magnetic or electromagnetic leakage fields
• CPC Class Codes: H02J 7/0042 characterised by the mechanical construction
• CPC Class Codes: H04B 5/24 Inductive coupling
• CPC Class Codes: H04B 5/263 Multiple coils at either side
• CPC Class Codes: H04B 5/79 for data transfer in combination with power transfer
• CPC Class Codes: H05K 9/0007 Casings standardised racks H05K9/0062

Abstract

Embodiments describe a wireless charging transmitter coil includes: a support structure having an outer perimeter surrounding a contact housing and having first and second channels extending from the outer perimeter to the contact housing; first and second contacts positioned within the contact housing; and a wire wound around the outer perimeter of the support structure, the wire having a first end that extends through the first channel and a second end that extends through the second channel.

Claims

1. A wireless charging transmitter coil comprising:

a support structure having an outer perimeter surrounding a contact housing and having first and second channels extending from the outer perimeter to the contact housing;

first and second contacts positioned within the contact housing; and

a wire wound around the outer perimeter of the support structure, the wire having a first end that extends through the first channel and a second end that extends through the second channel.

2. The wireless charging transmitter coil of claim 1, wherein the first and second contacts are positioned at the center of the support structure.

3. The wireless charging transmitter coil of claim 1, further comprising first and second contact pads coupled to the first and second contacts, respectively.

4. The wireless charging transmitter coil of claim 3, wherein the first end and the second end of the wire are coupled to the first and second contact pads.

5. The wireless charging transmitter coil of claim 3, wherein the contact housing protrudes past a plane of the wire, and wherein the first and second contacts protrude past the contact housing.

6. The wireless charging transmitter coil of claim 1, wherein the coil has substantially planar top and bottom surfaces.

7. The wireless charging transmitter coil of claim 1, wherein the support structure is substantially circular in shape.

8. The wireless charging transmitter coil of claim 1, wherein the first and second channels are arranged at an angle with respect to each other.

9. The wireless charging transmitter coil of claim 1, further comprising one or more openings within the support structure for picking up and placing the wireless charging transmitter coil during assembly.

10. A wireless charging device configured to wirelessly charge an electronic device, the wireless charging device comprising:

a housing having a charging surface, the housing including first and second walls that define an interior cavity;

a transmitter coil arrangement disposed within the interior cavity, each transmitter coil of the transmitter coil arrangement comprises;

a support structure having an outer perimeter surrounding a contact housing and having first and second channels extending from the outer perimeter to the contact housing;

first and second contacts positioned within the contact housing; and

a wire wound around the outer perimeter of the support structure, the wire having a first end that extends through the first channel and a second end that extends through the second channel.

11. The wireless charging device of claim 10, wherein the first and second contacts are positioned at the center of the support structure.

12. The wireless charging device of claim 10, further comprising first and second contact pads coupled to the first and second contacts, respectively.

13. The wireless charging device of claim 12, wherein the first end and the second end of the wire are coupled to the first and second contact pads.

14. The wireless charging device of claim 12, wherein the contact housing protrudes past a plane of the wire, and wherein the first and second contacts protrude past the contact housing.

15. The wireless charging device of claim 10, wherein the wire is coated with an insulating layer.

16. The wireless charging device of claim 10, wherein the first and second channels are arranged at an angle with respect to each other.

17. The wireless charging device of claim 10, further comprising one or more openings within the support structure for picking up and placing the transmitter coil during assembly.

18. A wireless charging system, comprising:

an electrical device comprising a receiver coil configured to generate a current to charge a battery when exposed to a time-varying magnetic flux; and

a wireless charging mat configured to generate the time-varying magnetic flux to wirelessly charge the electrical device, the wireless charging mat comprising;

a housing having a charging surface, the housing including first and second walls that define an interior cavity;

a transmitter coil arrangement disposed within the interior cavity, each transmitter coil of the transmitter coil arrangement comprises;

a support structure having an outer perimeter surrounding a contact housing and having first and second channels extending from the outer perimeter to the contact housing;

first and second contacts positioned within the contact housing; and

a wire wound around the outer perimeter of the support structure, the wire having a first end that extends through the first channel and a second end that extends through the second channel.

19. The wireless charging system of claim 18, wherein the first and second contacts are positioned at the center of the support structure.

20. The wireless charging system of claim 18, further comprising first and second contact pads coupled to the first and second contacts, respectively.