WIRELESS POWER CHARGING PAD AND METHOD OF CONSTRUCTION

• US 20130300202A1
• Filed: 11/05/2012
• Published: 11/14/2013
• 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 9,653,206 B2
• Time in Patent Office: Days
• US Class Current: 307/104
• 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: Y10T 29/49117 Conductor or circuit manufacturing

Abstract

Systems, methods and apparatus for a wireless power transfer are disclosed. In one aspect a wireless power transfer apparatus is provided. The apparatus includes a casing. The apparatus further includes an electrical component housed within the casing. The apparatus further includes a sheath housed within the casing. The apparatus further includes a conductive filament housed within the sheath. The electrical component is electrically connected with the conductive filament. The casing is filled with a settable fluid bound with the sheath to form a structural matrix.

Claims

1. A wireless power transfer apparatus, comprising:

a casing;

an electrical component housed within the casing;

a sheath housed within the casing; and

a conductive filament housed within the sheath, the electrical component being electrically connected with the conductive filament, the casing filled with a settable fluid, the settable fluid bound with the sheath to form a structural matrix.

2. The device of claim 1, wherein the sheath comprises a first insulating layer, and wherein the conductive filament is surrounded by a second insulating layer.

3. The device of claim 1, wherein the electrical component and the conductive filament form a circuit configured to transfer or receive power wirelessly.

4. The device of claim 1, wherein the conductive filament is one of a plurality of conductive filaments comprising Litz wire.

5. The device of claim 1, wherein the settable fluid comprises epoxy resin.

6. The device of claim 1, further comprising an insulating layer housed within the casing and one or more magnetically permeable members housed within the casing, the insulating layer configured to electrically insulate the conductive filament from the one or more magnetically permeable members.

7. The device of claim 6, wherein the insulating layer comprises biaxially oriented polyethylene terephthalate.

8. The device of claim 7, wherein the thickness of the insulating layer is between substantially 0.1 millimeters and substantially 1.5 millimeters.

9. The device of claim 6, wherein the insulating layer comprises apertures configured to accommodate fluid flow of the settable fluid throughout the casing.

10. The device of claim 1, further comprising an abrasion material layer configured to shield at least a portion of an area of the conductive filament.

11. The device of claim 10, wherein the portion of the area corresponds to locations subject to abrasion comprising at least one of entry points, exit points, overlaps or corners.

12. The device of claim 10, wherein the abrasion material layer comprises a heat shrink.

13. A method of constructing an impact resistive device, the method comprising:

assembling electronic components with conductive material to form conductive filaments in a casing, at least a part of the conductive filaments being within a sheath;

introducing a settable fluid into the casing; and

forming a structural matrix within the casing from the fluid substance and the conductive filaments, the settable fluid binding with the sheath.

14. The method of claim 13, wherein the sheath comprises a first insulating layer, and wherein each of the conductive filaments is surrounding by a second insulating layer.

15. The method of claim 13, wherein the device comprises a pad configured to transfer or receive power wirelessly.

16. The method of claim 13, wherein the conductive filaments comprise Litz wire.

17. The method of claim 13, wherein the settable fluid comprises epoxy resin.

18. The method of claim 13, further comprising assembling an insulating layer and one or more magnetically permeable members, the insulating layer configured to electrically insulate the conductive filaments from the one or more magnetically permeable members.

19. The method of claim 18, wherein the insulating layer comprises biaxially oriented polyethylene terephthalate.

20. The method of claim 19, wherein the thickness of the insulating layer is between substantially 0.1 millimeters and substantially 1.5 millimeters.

21. The method of claim 18, wherein the insulating layer comprises apertures configured to accommodate fluid flow of the settable fluid throughout the casing.

22. The method of claim 13, further comprising:

heating the settable fluid sufficiently to soften the fluid after the fluid at least partially hardens;

moving the conductive filaments to a desired position while the fluid is in a softened state; and

allowing the fluid to re-harden.

23. The method of claim 22, wherein heating the settable fluid comprising heating the settable fluid with hot air.

24. The method of claim 13 further comprising:

determining sites where abrasion of the conductive filaments occurs; and

applying an abrasion resistant layer to selected areas on the conductive filaments such that when the conductive filament is in position in the casing the conductive filaments are shielded by the abrasion resistant layer at the sites for abrasion.

25. The method of claim 24, wherein the potential sites comprise at least one of entry points, exit points, overlaps or corners.

26. The method of claim 24, further comprising:

heating the abrasion resistant layer sufficiently to soften the abrasion resistant layer;

moving the conductive filaments to a desired position while the abrasion resistant layer is in a softened state; and

allowing the abrasion resistant layer to re-harden.

27. The method of claim 26, wherein heating the abrasion resistant layer comprises heating the abrasion resistant layer with hot air.

28. A wireless power transfer apparatus, comprising:

means for encasing electrical components;

means for conducting electricity; and

means for wrapping the means for conducting, the means for encasing filled with a settable fluid bound to the means for wrapping to form a structural matrix.

29. The device of claim 28, further comprising means for wirelessly transferring or receiving power wirelessly via the means for conducting.

30. The device of claim 28, further comprising means for insulating one or more magnetically permeable members from the means for conducting.

31. The device of claim 30, wherein means for insulating comprises biaxially oriented polyethylene terephthalate.

32. The device of claim 28, wherein the means for conducting comprises Litz wire, and wherein the means for wrapping comprises a sheath.