Battery wireless charging system

• US 10,277,055 B2
• Filed: 02/26/2016
• Issued: 04/30/2019
• Est. Priority Date: 02/26/2015
• Status: Active Grant

• Current Assignee: Greatbatch Limited (Greatbatch Incorporated)
• Original Assignee: Greatbatch Limited (Greatbatch Incorporated)
• Inventors: Peterson, Brian R., Jankins, Eric, Robnett, Ronald H.
• Primary Examiner(s): Tat, Binh
• Application Number:
  US15/055,063
• Publication Number:
  US 20160254694A1
• Time in Patent Office: 1,159 Days
• Field of Search: 320106-115
• 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 50/90 involving detection or optimisation of position, e.g. alignment
• CPC Class Codes: H02J 7/00 Circuit arrangements for charging or depolarising batteries or for supplying loads from batteries
• CPC Class Codes: H02J 7/0044 specially adapted for holding portable devices containing batteries H02J7/0045 takes precedence

Abstract

A system for wirelessly charging an electrical energy storage device such as an electrochemical cell or battery pack is described. The system comprises a transmitting base unit having a charging tray that is capable of wirelessly transmitting electrical power received from an external electrical energy source. In addition, the system comprises an electrical energy capture assembly that is electrically incorporatable with an energy storage device. The energy capture assembly comprises a receiving coil that is electrically connected to various sub-circuits that condition and modify the wirelessly received electrical energy so that it re-charges the energy storage device. The system is primarily designed to be used with electrical power that is wirelessly transmitted by near field magnetic induction. The circuitry of the system is designed to accommodate for fluctuations in magnitude of wirelessly transmitted electrical power. In addition, system is designed to optimally utilize wireless near field magnetic induction electrical power.

Claims

1. A base unit for wirelessly charging an electrical energy storage device, the base unit comprising:

a) a housing comprising a housing upper surface and a housing lower surface, wherein a tray portion of the housing is configured to contain at least one electrical energy storage device that is intended to be charged, the tray portion of the housing comprising a tray platform that resides in a first plane and is recessed inwardly from the housing upper surface towards the housing lower surface;

b) an electrical energy supply unit positioned inside the housing and being electrically connectable to an external electrical power supply;

c) a main circuit board positioned inside the housing and being electrically powered by the electrical energy supply unit; and

d) an antenna circuit board positioned inside the housing and being electrically connected to the main circuit board, wherein the antenna circuit board supports a wireless energy transmitting antenna comprising a resonant inductor coil that resides in a second plane spaced from the first plane of the tray platform, the resonant inductor coil being configured to wirelessly transmit electrical energy to charge an electrical energy storage device supported on the tray platform,

e) wherein the first plane of the tray platform and the second plane of the resonant inductor coil are parallel to and aligned with each other.

2. The base unit of claim 1, wherein the main circuit board supports an electrical energy transmitting circuit, the electrical energy transmitting circuit comprising a power management sub-circuit having a first integrated circuit electrically connected to a clock signal circuit comprising an AND gate, a NAND gate, a first field emission transistor, and a second field emission transistor.

3. The base unit of claim 2, wherein the electrical energy transmitting circuit comprises an inverter sub-circuit that is electrically connected to the antenna circuit board, and wherein the wireless energy transmitting antenna supported on the antenna circuit board and comprising the resonant inductor coil is electrically connected to a first set of field emission transistors (Q₉, Q₁₂) and a second set of field emission transistors (Q₁₀, Q₁₁), and wherein alternating open and closed positions of the respective first and second sets of field emission transistors causes an electrical power having an alternating current to flow across the resonant inductor coil.

4. The base unit of claim 3, wherein the electrical energy transmitting circuit comprises a pulse width modulator sub-circuit electrically connected to the inverter sub-circuit, the pulse width modulator sub-circuit comprising a clock resonator source and the AND gate electrically connected in parallel with the NAND gate, and wherein the pulse width modulator sub-circuit is configured to provide a clock reference signal to the inverter sub-circuit.

5. The base unit of claim 1, wherein the tray portion of the housing comprises a tray perimeter sidewall that extends from the housing upper surface to the tray platform.

6. The base unit of claim 1, wherein the tray platform is spaced from the antenna circuit board by a first gap that ranges from about 0.1 mm to about 5 mm.

7. The base unit of claim 1, wherein the housing lower surface comprises a contoured lower surface portion disposed between a first foot that is spaced apart from a second foot.

8. The base unit of claim 7, wherein the antenna circuit board is spaced from the first foot by a second gap that ranges from about 2.5 cm to about 10 cm.

9. The base unit of claim 5, wherein the tray perimeter sidewall extends from the housing upper surface to the tray platform at an angle ranging from about 10°

to about 90°

with respect to a plane of the housing upper surface.

10. The base unit of claim 5, wherein the tray perimeter sidewall and the tray platform are not provided with a resonant inductor coil.

11. The base unit of claim 1, wherein the tray platform comprises a tray platform perimeter residing along the first plane, and wherein, with respect to an imaginary projection of the tray platform onto the resonant inductor coil, an outer perimeter of the resonant inductor coil extends laterally outwardly beyond the tray platform perimeter.

12. The base unit of claim 11, wherein the resonant inductor coil has a spiral shape residing in the second plane.

13. The base unit of claim 11, wherein the outer perimeter of the resonant inductor coil extends laterally outwardly beyond the tray platform perimeter by a distance that ranges from about 1 mm to about 10 mm.

14. The base unit of claim 1, wherein the tray portion of the housing has a depth measured from the tray upper surface to the tray platform that ranges from about 0.5 cm to about 25 cm.

15. A base unit for wirelessly charging an electrical energy storage device, the base unit comprising:

a) a housing comprising a housing upper surface and a housing lower surface, wherein a tray portion of the housing is configured to contain at least one electrical energy storage device that is intended to be charged, the tray portion of the housing comprising a tray platform residing in a first plane and being recessed inwardly from the housing upper surface towards the housing lower surface, wherein the tray platform comprises a tray platform perimeter residing in the first plane;

b) an electrical energy supply unit positioned inside the housing and being electrically connectable to an external electrical power supply;

c) a main circuit board positioned inside the housing and being electrically powered by the electrical energy supply unit; and

d) an antenna circuit board positioned inside the housing and being electrically connected to the main circuit board, wherein the antenna circuit board supports a wireless energy transmitting antenna comprising a resonant inductor coil residing in a second plane spaced from the first plane of the tray platform, the resonant inductor coil being configured to wirelessly transmit electrical energy to charge an electrical energy storage device supported on the tray platform,

e) wherein the first plane of the tray platform and the second plane of the resonant inductor coil are parallel to and aligned with each other, and wherein, with respect to an imaginary projection of the tray platform onto the resonant inductor coil, an outer perimeter of the resonant inductor coil extends laterally outwardly beyond the tray platform perimeter by a distance that ranges from about 1 mm to about 10 mm.

16. The base unit of claim 15, wherein the resonant inductor coil has a spiral shape residing in the second plane.

17. The base unit of claim 15, wherein the tray perimeter sidewall and the tray platform are not provided with a resonant inductor coil.

18. The base unit of claim 15, wherein the tray portion of the housing has a depth measured from the tray upper surface to the tray platform that ranges from about 0.5 cm to about 25 cm.

19. A base unit for wirelessly charging an electrical energy storage device, the base unit comprising:

a) a housing comprising a housing upper surface and a housing lower surface, wherein a tray portion of the housing is configured to contain at least one electrical energy storage device that is intended to be charged, the tray portion of the housing comprising a tray platform residing in a first plane and being recessed inwardly from the housing upper surface towards the housing lower surface, wherein the tray platform comprises a tray platform perimeter residing in the first plane;

b) an electrical energy supply unit positioned inside the housing and being electrically connectable to an external electrical power supply;

c) a main circuit board positioned inside the housing and being electrically powered by the electrical energy supply unit; and

d) an antenna circuit board positioned inside the housing spaced from the tray platform and being electrically connected to the main circuit board, wherein the antenna circuit board supports a wireless energy transmitting antenna comprising a resonant inductor coil having a spiral shape residing in a second plane, the resonant inductor coil being configured to wirelessly transmit electrical energy to charge an electrical energy storage device supported on the tray platform,

e) wherein the first plane of the tray platform and the second plane of the resonant inductor coil are parallel to and aligned with each other, and

f) wherein, with respect to an imaginary projection of the tray platform onto the resonant inductor coil, an outer perimeter of the resonant inductor coil extends laterally outwardly beyond the tray platform perimeter.

20. The base unit of claim 19, wherein the outer perimeter of the resonant inductor coil extends laterally outwardly beyond the tray platform perimeter by a distance that ranges from about 1 mm to about 10 mm.

21. The base unit of claim 19, wherein the tray perimeter sidewall and the tray platform are not provided with a resonant inductor coil.