ASYMMETRICALLY LAYERED STACKED COILS AND/OR CHAMFERED FERRITE IN WIRELESS POWER TRANSFER APPLICATIONS

• US 20160204618A1
• Filed: 07/27/2015
• Published: 07/14/2016
• Est. Priority Date: 01/14/2015
• Status: Active Grant

• Current Assignee: WiTricity Corporation
• Original Assignee: Qualcomm, Inc.
• Inventors: Samuelsson, Johan Gabriel, Skowron, Maciej Krzysztof, Werner, Michael
• Granted Patent: US 9,912,172 B2
• Time in Patent Office: Days
• US Class Current: 1/1
• 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 41/071 Winding coils of special form winding conductors onto closed formers or cores H01F41/08
• CPC Class Codes: H01F 41/074 Winding flat coils
• CPC Class Codes: H01F 5/02 wound on non-magnetic supports, e.g. formers
• CPC Class Codes: H02J 50/005 Mechanical details of housing or structure aiming to accommodate the power transfer means, e.g. mechanical integration of coils, antennas or transducers into emitting or receiving devices
• CPC Class Codes: H02J 50/10 using inductive coupling
• CPC Class Codes: H02J 50/12 of the resonant type

Abstract

An apparatus for wirelessly transferring power comprises a first coil having a first winding path and a second winding path. The apparatus comprises a holder configured to hold the first coil and the second coil in a predetermined winding pattern. Each of the first and second winding paths comprise a plurality of successive winding groups. In each of the plurality of successive winding groups, at least a portion of each winding of consecutive windings is disposed on top of an immediately previous winding on the holder for a predetermined number of windings. Each of the successive winding groups of the first winding path is disposed along an outer perimeter of an immediately previous winding group and each of the successive winding groups of the second winding path is disposed along an inner perimeter of an immediately previous winding group.

Claims

1. An apparatus for wirelessly transferring charging power, comprising:

a first coil having a first winding path;

a second coil having a second winding path; and

a holder configured to hold the first coil and the second coil in a predetermined winding pattern,

wherein each of the first winding path and the second winding path comprise a plurality of successive winding groups and, in each of the plurality of successive winding groups, at least a portion of each winding of consecutive windings is disposed on top of an immediately previous winding on the holder for a predetermined number of windings, and

wherein each of the successive winding groups of the first winding path is disposed along an outer perimeter of an immediately previous winding group and each of the successive winding groups of the second winding path is disposed along an inner perimeter of an immediately previous winding group.

2. The apparatus of claim 1, wherein the holder further comprises a plurality of guides for guiding the windings of each of the first coil and the second coil.

3. The apparatus of claim 1, wherein the first winding path of the first coil is wound in one of a clockwise direction and a counterclockwise direction and the second winding path of the second coil is wound in the other of the clockwise direction and the counterclockwise direction in the holder.

4. The apparatus of claim 1, wherein the first coil and the second coil are disposed adjacent to and sufficiently close to one another such that a gap large enough to route either of the first winding path and the second winding path is not present between the first coil and the second coil.

5. The apparatus of claim 1, further comprising a ferrite plate having a chamfered edge, the chamfered edge configured to provide a space for a conductor of at least one of the first coil and the second coil to transition from a first layer of windings to a second layer of windings that is disposed closer to the ferrite plate than the first layer of windings.

6. The apparatus of claim 5, wherein the space comprises a portion of the ferrite plate removed by the chamfered edge.

7. The apparatus of claim 5, wherein at least a portion of the ferrite plate is disposed in a plane in which the second layer of windings is wound.

8. The apparatus of claim 5, wherein at least a portion of the chamfered edge extends laterally over a region where the conductor of the first coil and the second coil transitions from the first layer of windings to the second layer of windings.

9. A method for wirelessly transferring charging power, comprising:

energizing each of a first coil and a second coil disposed in a holder with an electrical current, the first coil having a first winding path and the second coil having a second winding path, and

wirelessly transferring charging power via the first coil and the second coil,

wherein each of the first winding path and the second winding path comprise a plurality of successive winding groups and, in each of the plurality of successive winding groups, at least a portion of each winding of consecutive windings is disposed on top of an immediately previous winding on the holder for a predetermined number of windings, and

wherein each of the successive winding groups of the first winding path is disposed along an outer perimeter of an immediately previous winding group and each of the successive winding groups of the second winding path is disposed along an inner perimeter of an immediately previous winding group.

10. The method of claim 9, wherein the holder comprises a plurality of guides for guiding the windings of each of the first coil and the second coil.

11. The method of claim 9, wherein the first winding path of the first coil is wound in one of a clockwise direction and a counterclockwise direction and the second winding path of the second coil is wound in the other of the clockwise direction and the counterclockwise direction in the holder.

12. The method of claim 9, wherein the first coil and the second coil are disposed adjacent to and sufficiently close to one another such that a gap large enough to route either of the first winding path and the second winding path is not present between the first coil and the second coil.

13. The method of claim 9, wherein a ferrite plate has a chamfered edge configured to provide a space for a conductor of at least one of the first coil and the second coil to transition from a first layer of windings to a second layer of windings that is disposed closer to the ferrite plate than the first layer of windings.

14. The method of claim 13, wherein the space comprises a portion of the ferrite plate removed by the chamfered edge.

15. The method of claim 13, wherein at least a portion of the ferrite plate is disposed in a plane in which the second layer of windings is wound.

16. The method of claim 13, wherein at least a portion of the chamfered edge extends laterally over a region where the conductor of the first coil and the second coil transitions from the first layer of windings to the second layer of windings.

17. A non-transitory, computer-readable medium comprising code that, when executed, causes an apparatus for wirelessly transferring charging power to perform a method comprising:

energizing each of a first coil and a second coil disposed in a holder with an electrical current, the first coil having a first winding path and the second coil having a second winding path,

wirelessly transferring charging power via the first coil and the second coil,

wherein each of the first winding path and the second winding path comprise a plurality of successive winding groups and, in each of the plurality of successive winding groups, at least a portion of each winding of consecutive windings is disposed on top of an immediately previous winding on the holder for a predetermined number of windings, and

wherein each of the successive winding groups of the first winding path is disposed along an outer perimeter of an immediately previous winding group and each of the successive winding groups of the second winding path is disposed along an inner perimeter of an immediately previous winding group.

18. The medium of claim 17, wherein the holder comprises a plurality of guides for guiding the windings of each of the first coil and the second coil.

19. The medium of claim 17, wherein the first winding path of the first coil is wound in one of a clockwise direction and a counterclockwise direction and the second winding path of the second coil is wound in the other of the clockwise direction and the counterclockwise direction in the holder.

20. The medium of claim 17, wherein the first coil and the second coil are disposed adjacent to and sufficiently close to one another such that a gap large enough to route either of the first winding path and the second winding path is not present between the first coil and the second coil.

21. The medium of claim 17, wherein a ferrite plate has a chamfered configured to provide a space for a conductor of at least one of the first coil and the second coil to transition from a first layer of windings to a second layer of windings that is disposed closer to the ferrite plate than the first layer of windings.

22. The medium of claim 21, wherein the space comprises a portion of the ferrite plate removed by the chamfered edge.

23. The medium of claim 21, wherein at least a portion of the ferrite plate is disposed in a plane in which the second layer of windings is wound.

24. The medium of claim 21, wherein at least a portion of the chamfered edge extends laterally over a region where the conductor of the first coil and the second coil transitions from the first layer of windings to the second layer of windings.

25. A method for fabricating an apparatus for wirelessly transferring charging power, the method comprising:

winding a first coil in a holder along a first winding path and comprising plurality of successive winding groups, each of the plurality of successive winding groups being disposed along an outer perimeter of an immediately previous winding group,

winding a second coil in the holder along a second winding path and comprising a plurality of successive winding groups, each of the plurality of successive winding groups being disposed along an inner perimeter of an immediately previous winding group, and

wherein in each of the plurality of successive winding groups of each of the first winding path and the second winding path, at least a portion of each winding of consecutive windings is disposed on top of an immediately previous winding on the holder for a predetermined number of windings.

26. The method of claim 25, wherein the holder comprises a plurality of guides for guiding the windings of each of the first coil and the second coil.

27. The method of claim 25, further comprising:

winding the first winding path of the first coil in one of a clockwise direction and a counterclockwise direction in the holder, and

winding the second winding path of the second coil in the other of the clockwise direction and the counterclockwise direction in the holder.

28. The method of claim 25, further comprising connecting the first coil in series with the second coil.

29. The method of claim 25, wherein the first coil and the second coil are wound from the same conductor.

30. The method of claim 25, wherein the first coil and the second coil are disposed adjacent to and sufficiently close to one another such that a gap large enough to route either of the first winding path and the second winding path is not present between the first coil and the second coil.