Wireless power supply system and multi-layer shim assembly
First Claim
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1. A multi-layer shim assembly for use in positioning an upper plurality of wireless power coils and a lower plurality of wireless power coils in a multi-layer coil array, said multi-layer shim assembly comprising:
- a first shim layer including a first guide portion for aligning said upper plurality of wireless power coils in said multi-layer coil array and a first routing portion for routing electrical connections from each of said upper plurality of wireless power coils, wherein said first shim layer includes a major surface, and wherein said first guide portion includes a first wall portion extending from said major surface to define a first recess to simultaneously encompass said upper plurality of wireless power coils therein, said first wall portion encompassing said upper plurality including at least two wireless power coils; and
a second shim layer joined with said first shim layer, said second shim layer including a second guide portion for aligning said lower plurality of wireless power coils in said multi-layer coil array and a second routing portion for routing electrical connections from each of said lower plurality of wireless power coils, wherein said second shim layer includes a major surface, and wherein said second guide portion includes a second wall portion extending from said major surface to define a second recess to simultaneously encompass said lower plurality of wireless power coils therein, said second wall portion encompassing said lower plurality including at least two wireless power coils,wherein said first guide portion and said second guide portion cooperate to align said plurality of wireless power coils in a predefined, overlapping, coil array, wherein said first recess is offset with respect to said second recess such that said upper plurality of wireless power coils is substantially axially offset with respect to said lower plurality of wireless power coils when received within said first and second recesses, respectively.
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Abstract
A wireless power supply includes a multi-layer shim assembly. Each shim aids in alignment of coils and routing of conductors in a multi-layer coil array. A shield or PCB can be used as part of the multi-layer shim assembly. Wires can be routed through channels to the edge of the shim assembly or wires can protrude through a portion of the multi-layer shim assembly. Traces can be used to route current through the multi-layer shim assembly. Plastic shims can be created by over-molding coils with plastic.
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Citations
21 Claims
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1. A multi-layer shim assembly for use in positioning an upper plurality of wireless power coils and a lower plurality of wireless power coils in a multi-layer coil array, said multi-layer shim assembly comprising:
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a first shim layer including a first guide portion for aligning said upper plurality of wireless power coils in said multi-layer coil array and a first routing portion for routing electrical connections from each of said upper plurality of wireless power coils, wherein said first shim layer includes a major surface, and wherein said first guide portion includes a first wall portion extending from said major surface to define a first recess to simultaneously encompass said upper plurality of wireless power coils therein, said first wall portion encompassing said upper plurality including at least two wireless power coils; and a second shim layer joined with said first shim layer, said second shim layer including a second guide portion for aligning said lower plurality of wireless power coils in said multi-layer coil array and a second routing portion for routing electrical connections from each of said lower plurality of wireless power coils, wherein said second shim layer includes a major surface, and wherein said second guide portion includes a second wall portion extending from said major surface to define a second recess to simultaneously encompass said lower plurality of wireless power coils therein, said second wall portion encompassing said lower plurality including at least two wireless power coils, wherein said first guide portion and said second guide portion cooperate to align said plurality of wireless power coils in a predefined, overlapping, coil array, wherein said first recess is offset with respect to said second recess such that said upper plurality of wireless power coils is substantially axially offset with respect to said lower plurality of wireless power coils when received within said first and second recesses, respectively. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 17)
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12. A multi-layer shim assembly for use in positioning a first and second plurality of wireless power coils in a multi-layer coil array, said multi-layer shim assembly comprising:
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a first shim layer including a major surface, a first guide portion for aligning said first plurality of wireless power coils in said multi-layer coil array, and a first routing portion for routing electrical connections from each of said first plurality of wireless power coils, wherein said first guide portion and said first routing portion each include a wall portion extending from said upper surface to define a recess in said first shim layer to simultaneously encompass said first plurality of wireless power coils and said electrical connections, respectively; and a printed circuit board forming a second shim layer including said second plurality of wireless power coils in said multi-layer coil array printed on said printed circuit board and a second routing portion including a printed circuit board trace network, wherein said first guide portion aligns said first plurality of wireless power coils in a predefined, overlapping, array with respect to said second plurality of wireless power coils such that said first plurality of wireless power coils is substantially axially offset with respect to said second plurality of wireless power coils. - View Dependent Claims (13, 14, 15, 16)
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18. A multi-layer shim assembly comprising:
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an upper shim layer including a first recess that is shaped to simultaneously receive each of a first plurality of wireless power coils therein, the upper shim layer including a first plurality of traces to extend from each of the first plurality wireless power coils; a middle shim layer including a second recess that is shaped to simultaneously receive each of a second plurality of wireless power coils therein, the middle shim layer including a second plurality of traces to extend from each of the second plurality of wireless power coils, a lower shim layer including a third recess that is shaped to simultaneously receive each of a third plurality of wireless power coils therein, the lower shim layer including a third plurality of traces to extend from each of the third plurality of wireless power coils, wherein the first, second and third recesses are axially offset with respect to each other to align the first, second and third plurality of wireless power coils in a predefined partially overlapping three-dimensional coil array when the first, second and third plurality of wireless power coils are received within their respective recesses. - View Dependent Claims (19, 20, 21)
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Specification