WIRELESS POWER TRANSFER APPARATUS AND METHOD OF MANUFACTURE

• US 20130249477A1
• 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 9,431,834 B2
• Time in Patent Office: Days
• US Class Current: 320/108
• CPC Class Codes: H01F 27/02 Casings
• 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: H02J 7/0042 characterised by the mechanical construction
• CPC Class Codes: Y10T 29/49002 Electrical device making

Abstract

Systems, methods and apparatuses for wireless power transfer are disclosed. In one aspect, a wireless power transfer apparatus is provided comprising a casing with at least one projecting member projecting from an inner side of the surface of the casing that is subject to external compression forces. An induction coil and other components such as insulating layers and magnetically permeable members are positioned around at least one of the projecting members and maintained in position by the projecting members. The wireless power transfer apparatus is able to withstand large compressive forces, such as those imparted by heavy vehicles and the like passing over the apparatus when positioned on the ground in a wireless power transfer system.

Claims

1. A wireless power transfer apparatus comprising:

a first casing portion having a wall with a projecting member extending from an inner surface of the wall;

a coil configured to wirelessly receive or transmit power, the coil extending around the projecting member; and

a second casing portion connected to the first casing portion to form a chamber within which the coil is housed.

2. The wireless power transfer apparatus of claim 1, wherein the wall of the first casing portion is configured to withstand external compression forces.

3. The wireless power transfer apparatus of claim 1, wherein the projecting member abuts an inner surface of the second casing portion and comprises a material able to withstand external compression forces applied to the wall of the first casing portion during use.

4. The wireless power transfer apparatus of claim 1, wherein the projecting member and an inner surface of the second casing portion come into contact when the wall of the first casing portion deforms under a compression force.

5. The wireless power transfer apparatus of claim 1, wherein the projecting member is integrally formed with the wall of the first casing portion.

6. The wireless power transfer apparatus of claim 1, wherein the coil is wound around the projecting member.

7. The wireless power transfer apparatus of claim 1, wherein the coil is wound around a plurality of projecting members extending from the inner surface of the wall of the first casing portion.

8. The wireless power transfer apparatus of claim 1, wherein the projecting member comprises a pillar.

9. The wireless power transfer apparatus of claim 1, further comprising a component located within the chamber and held in position by the projecting member.

10. The wireless power transfer apparatus of claim 9, wherein the component is selected from the group comprising:

a magnetically permeable member, an electrically insulating member, or a physical protection member.

11. A method of manufacturing a wireless power transfer apparatus comprising:

positioning a coil around a projecting member extending from an inner surface of a wall of a first casing portion, the coil configured to wirelessly receive or transmit power and the wall configured to withstand external compression forces; and

connecting a second casing portion to the first casing portion to form a chamber within which the coil is housed.

12. The method of claim 11, wherein positioning the coil around the projecting member comprises winding a length of conducting material around the projecting member.

13. The method of claim 11, further comprising positioning a component on top of the coil such that the component is held in position by the projecting member before connecting the second casing portion to the first casing portion.

14. A wireless power transfer apparatus comprising:

first casing means for defining a portion of a chamber, the first casing means having an inner surface;

means for providing internal structural support located on and projecting from the inner surface of the first casing means;

means for conveying electric current, wherein the means for conveying electric current is positioned to extend around the means for providing internal structural support and is configured to wirelessly receive or transmit power; and

second casing means for defining a further portion of the chamber, the second casing means secured to the first casing means to form the chamber for housing the means for conveying electric current.

15. The wireless power transfer apparatus of claim 14, wherein the means for providing internal structural support abuts an inner surface of the second casing means at least when an external compression force applied to an outer surface of the first casing means causes the first casing means to deform, and wherein the means for providing internal structural support is configured to withstand external compression forces applied to the outer surface of the first casing means.

16. The wireless power transfer apparatus of claim 14, wherein the means for providing internal structural support is integrally formed with the first casing means.

17. The wireless power transfer apparatus of claim 14, wherein the means for conveying electric current is wound around the means for providing internal structural support.

18. The wireless power transfer apparatus of claim 14, further comprising a component held in position by the means for providing internal structural support.

19. The wireless power transfer apparatus of claim 18, wherein the component is selected from the group comprising:

means for strengthening formation of an electromagnetic field, means for electrically insulating the means for conveying electric current, or means for physically protecting the means for conveying electric current.