Wireless power charging pad and method of construction

• US 9,653,206 B2
• Filed: 11/05/2012
• Issued: 05/16/2017
• Est. Priority Date: 03/20/2012
• Status: Active Grant

• Current Assignee: WiTricity Corporation
• Original Assignee: Qualcomm, Inc.
• Inventors: Van Boheemen, Edward, Kissin, Michael, Beaver, Jonathan, Keeling, Nicholas A
• Primary Examiner(s): Fleming, Fritz M
• Assistant Examiner(s): SHIAO, DAVID A
• Application Number:
  US13/669,304
• Publication Number:
  US 20130300202A1
• Time in Patent Office: 1,653 Days
• Field of Search: None
• 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;

a plurality of conductive filaments housed within the sheath, each conductive filament comprising its own insulating coating, the electrical component being electrically coupled to the plurality of conductive filaments; and

a set insulating fluid that;

fills the casing,

penetrates the sheath, and

forms a structural matrix with the plurality of conductive filaments within the sheath.

2. The apparatus of claim 1, wherein the electrical component and the plurality of conductive filaments form a circuit configured to transfer or receive power wirelessly.

3. The apparatus of claim 1, wherein the plurality of conductive filaments form Litz wire.

4. The apparatus of claim 1, wherein the set insulating fluid comprises epoxy resin.

5. The apparatus of claim 1, further comprising an insulating layer housed within the casing and one or more ferromagnetic magnetically permeable members housed within the casing, the insulating layer configured to physically separate and electrically insulate the plurality of conductive filaments from the one or more ferromagnetic magnetically permeable members.

6. The apparatus of claim 5, wherein the insulating layer comprises biaxially oriented polyethylene terephthalate.

7. The apparatus of claim 6, wherein the thickness of the insulating layer is between 0.1 millimeters and 1.5 millimeters.

8. The apparatus of claim 5, wherein the insulating layer comprises apertures configured to accommodate fluid flow of the set insulating fluid throughout the casing.

9. The apparatus of claim 1, further comprising an abrasion material layer configured to shield at least a portion of an area of the plurality of conductive filaments.

10. The apparatus of claim 9, wherein the portion of the area corresponds to locations subject to abrasion comprising at least one of entry points, exit points, overlaps or corners.

11. The apparatus of claim 9, wherein the abrasion material layer comprises a heat shrink.

12. A wireless power transfer apparatus, comprising:

means for encasing electrical components;

an electrical component housed within the encasing means;

a plurality of means for conducting electricity;

means for isolating each means for conducting of the plurality of means for conducting; and

means for wrapping the plurality of means for conducting and each respective means for isolating, the electrical component electrically coupled to the plurality of means for conducting, the means for encasing filled with a set insulating fluid configured to;

penetrate the means for wrapping, and

form a structural matrix with the plurality of means for conducting and means for isolating.

13. The apparatus of claim 12, wherein the electrical component and the plurality of means for conducting are configured to form a circuit configured to wirelessly transfer or receive power.

14. The apparatus of claim 12, further comprising means for insulating one or more ferromagnetic, magnetically permeable members from the means for conducting.

15. The apparatus of claim 14, wherein the means for insulating comprises biaxially oriented polyethylene terephthalate.

16. The apparatus of claim 14, wherein the means for insulating comprises apertures configured to accommodate fluid flow of the set insulating fluid throughout the means for encasing.

17. The apparatus of claim 12, wherein the plurality of means for conducting comprises Litz wire, and wherein the means for wrapping comprises a sheath.

18. The apparatus of claim 12, further comprising means for shielding at least a portion of an area of the plurality of means for conducting electricity.

19. The apparatus of claim 18, wherein the portion of the area corresponds to locations subject to abrasion comprising at least one of entry points, exit points, overlaps or corners.

20. The apparatus of claim 18, wherein the means for shielding comprises a heat shrink.

21. A method for wirelessly transferring power with a wireless power transfer device, the method comprising:

coupling a wireless power transfer device to a magnetic field via an induction circuit comprising an electrical component and a plurality of conductive filaments housed within a sheath, each conductive filament comprising its own insulating coating, the electrical component, the plurality of conductive filaments, the insulating coatings, and the sheath all housed within a casing filled with a set insulating fluid that penetrates the sheath and forms a structural matrix with the insulating coating of each conductive filament within the sheath; and

transferring power via the magnetic field.

22. The method of claim 21, wherein the plurality of conductive filaments comprise Litz wire.

23. The method of claim 21, wherein the set insulating fluid comprises epoxy resin.

24. The method of claim 21, wherein the casing further houses an insulating layer casing and one or more ferromagnetic magnetically permeable members, the insulating layer configured to electrically insulate the plurality of conductive filaments from the one or more ferromagnetic magnetically permeable members.

25. The method of claim 24, wherein the insulating layer comprises biaxially oriented polyethylene terephthalate.

26. The method of claim 25, wherein the thickness of the insulating layer is between 0.1 millimeters and 1.5 millimeters.

27. The method of claim 24, wherein the insulating layer comprises apertures configured to accommodate fluid flow of the set insulating fluid throughout the casing.

28. The method of claim 21, wherein the casing further houses at least an abrasion material layer configured to shield a portion of an area of the conductive filaments.

29. The method of claim 28, wherein the portion of the area corresponds to locations subject to abrasion comprising at least one of entry points, exit points, overlaps or corners.

30. The method of claim 28, wherein the abrasion material layer comprises a heat shrink.