WIRELESS POWER TRANSFER DEVICE AND METHOD OF MANUFACTURE

• US 20130249304A1
• Filed: 11/07/2012
• Published: 09/26/2013
• Est. Priority Date: 03/20/2012
• Status: Active Grant

• Current Assignee: WiTricity Corporation
• Original Assignee: Qualcomm, Inc.
• Inventors: Keeling, Nicholas A., Van Boheemen, Edward, Kissin, Michael, Beaver, Jonathan
• Granted Patent: US 9,583,259 B2
• Time in Patent Office: Days
• US Class Current: 307/104
• CPC Class Codes: B60L 53/122 Circuits or methods for driving the primary coil, e.g. supplying electric power to the coil
• 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 27/022 Encapsulation
• CPC Class Codes: H01F 38/14 Inductive couplings for wireless supply or distribution of electric power using inductive coupling H02J50/10
• CPC Class Codes: H01F 41/00 Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties
• CPC Class Codes: H01F 41/005 Impregnating or encapsulating insulating of windings H01F41/12
• CPC Class Codes: H02J 7/0042 characterised by the mechanical construction
• 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 90/12 Electric charging stations
• CPC Class Codes: Y02T 90/14 Plug-in electric vehicles
• CPC Class Codes: Y10T 29/4902 Electromagnet, transformer or inductor

Abstract

Methods and apparatuses for wireless power transfer, and particularly, wireless power transfer to remote systems such as electric vehicles are disclosed. In one aspect, a wireless power transfer device is provided comprising a casing housing at least one component, with a first portion of the casing containing a set first flowable medium, and a second portion of the casing containing a second set flowable medium having a different density to that of the first set flowable medium. The casing can include a locating portion, with the locating portion in contact with a flowable medium set within the casing. In another aspect, a method of manufacturing a wireless power transfer device is provided. During manufacturing, a casing of the device may be loaded to maintain a desired shape while at least one component and a settable flowable medium are introduced into the casing.

Claims

1. A wireless power transfer device comprising:

a casing;

a coil configured to wirelessly receive and transmit power housed within the casing; and

a set first flowable medium contained in a first portion of the casing and surrounding at least part of the coil.

2. The device of claim 1, wherein a second portion of the casing comprises a set second flowable medium having a different density to that of the set first flowable medium.

3. The device of claim 2, comprising a magnetically permeable member, wherein at least part of the magnetically permeable member is held within the set second flowable medium.

4. The device of claim 1, wherein the casing comprises a locating portion in contact with the set first flowable medium.

5. The device of claim 4, wherein the locating portion comprises an undercutting portion.

6. The device of claim 4, wherein the locating portion comprises an aperture in the casing.

7. The device of claim 4, wherein the locating portion comprises a protrusion in the casing.

8. The device of claim 4, wherein the casing comprises a substantially chemically resistant material.

9. The device of claim 4, wherein the casing is made at least in part of polyethylene.

10. A method of manufacturing a wireless power transfer device including a casing and a coil configured to wirelessly receive and transmit power housed within the casing, the method comprising the steps of:

introducing the coil into the casing;

introducing a first flowable medium into the casing; and

causing the first flowable medium to set and form a set first flowable medium occupying a first portion of the casing surrounding at least part of the coil.

11. The method of claim 10, wherein the first flowable medium substantially fills the casing.

12. The method of claim 10, wherein the first flowable medium is epoxy resin.

13. The method of claim 10, wherein the casing of the wireless power transfer device includes a locating portion, and wherein upon causing the first flowable medium to set and form the set first flowable medium, the locating portion is in contact with the set first flowable medium.

14. The method of claim 10, further comprising:

introducing a second flowable medium of a different density to that of the first flowable medium into the casing and causing the second flowable medium to set and form a set second flowable medium, wherein the set second flowable medium occupies a second portion of the casing.

15. The method of claim 14, wherein the second flowable medium is of a lower density than the first flowable medium.

16. The method of claim 14, wherein the second flowable medium is epoxy resin mixed with a second material of a lower density than the epoxy resin.

17. The method of claim 14, further comprising introducing the second flowable medium after the first flowable medium has set.

18. The method of claim 14, wherein the first flowable medium and second flowable medium together substantially fill the casing.

19. The method of claim 14, wherein the wireless power transfer device further includes a magnetically permeable member, and wherein the method comprises:

introducing the first flowable medium into the casing such that upon setting of the first flowable medium, the coil is held within the set first flowable medium;

introducing the second flowable medium of a different density to that of the first flowable medium into the casing; and

causing the second flowable medium to set, wherein upon setting of the second flowable medium, at least part of the magnetically permeable member is held within the set second flowable medium.

20. The method of claim 19, wherein part of the magnetically permeable member is held within the set first flowable medium.

21. The method of claim 19, wherein the magnetically permeable member is encased by the set second flowable medium.

22. The method of claim 19, wherein the magnetically permeable member is encased by the set first flowable medium and the set second flowable medium.

23. A method of manufacturing a wireless power transfer device including a casing and a coil housed within the casing, the method comprising:

applying a force to the casing to maintain a desired shape;

introducing the coil into the casing;

introducing a medium in a flowable form into the casing such that upon setting of the medium, the coil is at least partially held within the medium; and

removing the applied force from the casing upon setting of the medium.

24. The method of claim 23, wherein the force is applied to a protrusion extending from an interior of the casing.

25. The method of claim 23, wherein the force is applied to the casing by applying a vacuum to an exterior of the casing.

26. The method of claim 23, wherein the medium in a set form maintains the shape of the casing on removal of the applied force.