CHARGING ASSEMBLY FOR WIRELESS POWER TRANSFER

• US 20170093198A1
• Filed: 09/30/2015
• Published: 03/30/2017
• Est. Priority Date: 09/30/2015
• Status: Active Grant

• Current Assignee: Apple Inc.
• Original Assignee: Apple Inc.
• Inventors: Graham, Christopher S., Thompson, Paul J.
• Granted Patent: US 10,424,962 B2
• Time in Patent Office: Days
• US Class Current: 1/1
• CPC Class Codes: H01F 27/02 Casings
• CPC Class Codes: H01F 27/36 Electric or magnetic shields or screens movable for varying inductance H01F21/10
• CPC Class Codes: H01F 27/361 made of combinations of electrically conductive material and ferromagnetic material
• 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 50/70 involving the reduction of electric, magnetic or electromagnetic leakage fields
• CPC Class Codes: H02J 7/0042 characterised by the mechanical construction
• CPC Class Codes: H02J 7/0044 specially adapted for holding portable devices containing batteries H02J7/0045 takes precedence
• CPC Class Codes: H04B 5/26 using coils
• CPC Class Codes: H04B 5/79 for data transfer in combination with power transfer

Abstract

A charging assembly for wireless power transfer. In embodiments, the charging assembly comprises a housing, a cap structure, a ferrimagnetic sleeve, an inductive coil, a magnet, a printed circuit board assembly (PCBA), and a four-pin connector extending from a bottom surface of the PCBA. A ridge of the cap structure can be coupled to a lip of the housing. The housing can include a bottom housing surface having an aperture, and a sidewall extending between the bottom housing surface and the lip that extends outward from the sidewall along a perimeter of the housing parallel to the bottom housing surface. The four-pin connector can extend through the aperture of the housing. Some embodiments are directed to a charging device that incorporates the charging assembly.

Claims

1. A wireless charging assembly comprising:

a housing including

a charging surface;

a ferrimagnetic sleeve disposed within the housing, the ferrimagnetic sleeve including first and second opposing faces, a central opening extending from the first face to the second face through the ferrimagnetic sleeve, and a recess surrounding the central opening and open at the first face;

an inductive coil disposed within the recess between the charging surface and the second face of the ferrimagnetic sleeve, the inductive coil configured to wirelessly transmit power across the charging surface; and

a magnet disposed within the central opening of the ferrimagnetic sleeve.

2. The wireless charging assembly of claim 1, further comprising an electromagnetic shield disposed between the charging surface of the housing and the inductive coil.

3. The wireless charging assembly of claim 1, wherein the housing further includes a plurality of protrusions, each protrusion including a threaded screw hole configured to receive a screw or bolt.

4. The wireless charging assembly of claim 1, wherein the housing comprises a cap structure coupled to a housing component, the housing component including an exterior surface and a sidewall extending between the exterior surface and a lip that extends outward from the sidewall, the lip of the housing component being coupled to the cap structure.

5. The wireless charging assembly of claim 1, further comprising:

a printed circuit board assembly (PCBA) disposed within the housing,

wherein the ferrimagnetic sleeve is disposed between the PCBA and the charging surface.

6. The wireless charging assembly of claim 5, wherein the PCBA comprises one or more contact pads configured to receive wires from the inductive coil.

7. The wireless charging assembly of claim 6 further comprising a guide element disposed in a notched portion of the ferrimagnetic sleeve, the guide element configured to guide the wires from the inductive coils to the one or more contact pads.

8. The wireless charging assembly of claim 5, further comprising:

a connector attached to the PCBA and extending from a surface of the PCBA through an aperture defined by an exterior surface of the housing, the connector being electrically coupled to the inductive coil.

9. The wireless charging assembly of claim 5,

wherein the PCBA defines a hollow portion in which the magnet is disposed.

10. The wireless charging assembly of claim 9, wherein the magnet is separated from both the PCBA and the ferrimagnetic sleeve by a casing disposed around the magnet.

11. A wireless charging assembly, comprising:

a housing including an exterior housing surface, a sidewall extending between the exterior housing surface and a lip that extends outward from the sidewall along a perimeter of the housing;

a cap structure having a charging surface and an interior-facing surface opposite the charging surface, the interior-facing surface coupled to the housing at the lip;

a ferrimagnetic sleeve disposed within the housing, the ferrimagnetic sleeve including first and second opposing faces, a central opening extending from the first face to the second face through the ferrimagnetic sleeve, and a recess surrounding the central opening and open at the first face;

an inductive coil disposed within the recess between the interior-facing surface and the second face of the ferrimagnetic sleeve, the inductive coil configured to wirelessly transmit power across the charging surface;

a magnet disposed within the central opening of the ferrimagnetic sleeve; and

a printed circuit board assembly (PCBA) disposed within the housing between the second face of the ferrimagnetic sleeve and the exterior housing surface; and

12. The wireless charging assembly of claim 11 further comprising an electromagnetic shield disposed between the interior-facing surface of the cap structure and the inductive coil.

13. The wireless charging assembly of claim 11, wherein the exterior housing surface further includes a plurality of protrusions, each protrusion including a threaded screw hole configured to receive a screw or a bolt.

14. The wireless charging assembly of claim 11 further comprising an adhesive material disposed between the cap structure and the housing.

15. The wireless charging assembly of claim 11, wherein the wireless charging assembly is substantially impermeable to liquids.

16. The wireless charging assembly of claim 11 wherein the PCBA comprises one or more contact pads configured to receive wires from the inductive coil.

17. The wireless charging assembly of claim 16 further comprising a guide element disposed in a notched portion of the ferrimagnetic sleeve, the guide element configured to guide the wires from the inductive coil to the one or more contact pads.

18. The wireless charging assembly of claim 11, wherein the PCBA comprises wireless charging circuit elements.

19. The wireless charging assembly of claim 11, wherein the PCBA includes a hollow portion in which the magnet is disposed.

20. The wireless charging assembly of claim 11, wherein the magnet is separated from both the PCBA and the ferrimagnetic sleeve by a casing disposed around the magnet.

21. (canceled)