Wireless power transfer systems containing foil-type transmitter and receiver coils

• US 9,123,466 B2
• Filed: 11/11/2013
• Issued: 09/01/2015
• Est. Priority Date: 11/11/2013
• Status: Active Grant

• Current Assignee: Eaton Intelligent Power Limited (Eaton Corporation PLC.)
• Original Assignee: Eaton Corp. (Wisconsin) (Eaton Corporation PLC.)
• Inventors: Zheng, Qingjie, Gu, Yilei, Wu, Tangshun, Zhao, Tiefu, Xu, Jun, Pahl, Birger, Hua, Yahan
• Primary Examiner(s): Lian, Mangtin
• Application Number:
  US14/076,930
• Publication Number:
  US 20150130583A1
• Time in Patent Office: 659 Days
• Field of Search: 336/84.R, 336/223, 336/232
• US Class Current: 1/1
• CPC Class Codes: H01F 2027/2838 using transposed wires
• CPC Class Codes: H01F 2027/2857 Coil formed from wound foil conductor
• CPC Class Codes: H01F 27/2823 Wires H01F27/2866 takes precedence
• CPC Class Codes: H01F 27/2847 Sheets; Strips H01F27/2866 takes precedence
• CPC Class Codes: H01F 38/14 Inductive couplings for wireless supply or distribution of electric power using inductive coupling H02J50/10

Abstract

Wireless power transfer systems include at least one foil-type transmitter/receiver coil with a plurality of turns, which is configured to reduce eddy current losses therein when energized to conduct an alternating current that supports inductive power transfer including coil-to-coil power electrical transfer, inductive heating, etc. The plurality of turns includes at least an outermost turn with a first arcuate-shaped corner having a concave inner surface, which faces an immediately adjacent one of the plurality of turns. The immediately adjacent one of the plurality of turns may also have a second arcuate-shaped corner with a concave inner surface facing an innermost one of the plurality of turns. The first arcuate-shaped corner may have a non-uniform radius of curvature and/or an innermost one of the plurality of turns may have an arcuate-shaped corner, which is a mirror image of the first arcuate-shaped corner when the coil is view in transverse cross-section.

Claims

1. A wireless power transfer system, comprising:

a foil-type transmitter coil having a plurality of turns including at least an outermost turn with at least a first arcuate-shaped corner having a concave inner surface facing a convex outer surface of an immediately adjacent one of the plurality of turns, said immediately adjacent one of the plurality of turns having at least a second arcuate-shaped corner with a concave inner surface facing a concave outer surface of an innermost one of the plurality of turns having an arcuate-shaped corner that is a mirror image of the first arcuate-shaped corner; and

wherein a middle one of the plurality of turns has flat inner and outer surfaces that face the innermost one of the plurality of turns and the outermost turn, respectively.

2. The system of claim 1, wherein a length of the second arcuate-shaped corner is greater than a length of the first arcuate-shaped corner.

3. The system of claim 1, wherein the first arcuate-shaped corner is sharper than the second arcuate-shaped corner.

4. The system of claim 1, wherein the first arcuate-shaped corner has a non-uniform radius of curvature.

5. The system of claim 1, wherein a next-to-innermost one of the plurality of turns has an arcuate-shaped corner that is a mirror image of the second arcuate-shaped corner.

6. The system of claim 1, wherein the middle one of the plurality of turns has a uniquely-shaped cross-section relative to all other turns in the plurality thereof.

7. The system of claim 1, wherein the plurality of turns are coplanar with each other.

8. The system of claim 1, wherein each of the plurality of turns overlaps at least partially with at least one of a next innermost turn and a next outermost turn.

9. The system of claim 1, wherein all of the plurality of turns within said foil-type transmitter coil are electrically shorted to each other as a continuous piece of foil.

10. A wireless power transfer system, comprising:

a foil-type coil having N turns electrically shorted together, where N is an integer greater than three, said N turns including;

an outermost turn having an at least partially concave inner surface facing a center of said foil-type coil, an innermost turn having an at least partially concave outer surface facing the at least partially concave inner surface of the outermost turn, a next-to-outermost turn having an at least partially concave inner surface facing the center of said foil-type coil, and a next-to-innermost turn having an at least partially concave outer surface facing the at least partially concave inner surface of the next-to-outermost turn;

wherein the outermost and innermost turns are mirror images of each other when viewed in cross-section and the next-to-outermost and next-to-innermost turns are mirror images of each other when viewed in cross-section; and

wherein each of the outermost, next-to-outermost, innermost and next-to-innermost turns has at least one arcuate-shaped corner.

11. The system of claim 10, wherein first and second opposing edges of the outermost turn have unequal shape when viewed in transverse cross-section.

12. The system of claim 11, wherein the first edge is arcuate-shaped and the second edge is flat.

13. The system of claim 12, further comprising a ferrite shielding cover extending adjacent the second edge of the outermost turn.

14. The system of claim 10, wherein a middle one of the plurality of turns has flat inner and outer surfaces.

15. The system of claim 10, wherein the outermost turn and the next-to-outermost turn have nonequivalent shapes when viewed in cross-section.

16. The system of claim 10, wherein the N turns are coplanar with each other.

17. The system of claim 10, wherein each of the N turns overlaps at least partially with at least one of a corresponding next innermost turn and a corresponding next outermost turn.