Enclosures for high power wireless power transfer systems

• US 10,574,091 B2
• Filed: 04/06/2016
• Issued: 02/25/2020
• Est. Priority Date: 07/08/2014
• Status: Active Grant

• Current Assignee: Witricity Corporation
• Original Assignee: Witricity Corporation
• Inventors: Kurs, Andre B., Lestoquoy, Guillaume
• Primary Examiner(s): Kessie, Daniel
• Assistant Examiner(s): Chowdhuri, Swarna N
• APPLICATION: US 20160233723A1
• Time in patent office: 1420 Days
• Field of Search: 307104
• CPC Class Codes: B60L 2210/10 DC to DC converters
• CPC Class Codes: B60L 2210/30 AC to DC converters
• CPC Class Codes: B60L 2210/40 DC to AC converters
• CPC Class Codes: B60L 2270/147 electro magnetic [EMI]
• CPC Class Codes: B60L 53/12 Inductive energy transfer
• CPC Class Codes: H01F 27/36 Electric or magnetic shields or screens movable for varying inductance H01F21/10
• CPC Class Codes: H01F 27/365 Magnetic shields or screens
• 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 5/005 with inductive power transfer for charging H02J7/025
• CPC Class Codes: H02J 50/12 of the resonant type
• CPC Class Codes: H02J 50/70 involving the reduction of electric, magnetic or electromagnetic leakage fields
• CPC Class Codes: Y02T 10/70 Energy storage systems for electromobility, e.g. batteries
• CPC Class Codes: Y02T 10/7005 Batteries
• CPC Class Codes: Y02T 10/7072 Electromobility specific charging systems or methods for batteries, ultracapacitors, supercapacitors or double-layer capacitors
• CPC Class Codes: Y02T 10/72 Electric energy management in electromobility
• CPC Class Codes: Y02T 10/7216 DC to DC power conversion
• CPC Class Codes: Y02T 10/7241 DC to AC or AC to DC power conversion
• CPC Class Codes: Y02T 90/12 Electric charging stations
• CPC Class Codes: Y02T 90/122 by inductive energy transmission
• CPC Class Codes: Y02T 90/127 Converters or inverters for charging
• CPC Class Codes: Y02T 90/14 : Plug-in electric vehicles

Abstract

The disclosure features wireless power devices for receiving power from a wireless power source. The devices include a first plurality of magnetic material pieces of substantially planar shape arranged in a first plane, where the first plurality of magnetic material pieces have a first planar surface and a second planar surface. The devices include a device resonator comprising at least one wound conductor disposed on the first planar surface and a second plurality of magnetic material pieces in a second plane, where at least one of the second plurality of magnetic material pieces overlaps at least one of the first plurality of magnetic material pieces and where a separation between the first and second planes is less than 2 mm.

Claims

1. A wireless power device for a vehicle, and for receiving power from a wireless power source comprising a source resonator, the wireless power device comprising:

a first plurality of magnetic material pieces arranged in a first plane, wherein the first plurality of magnetic material pieces have a first planar surface and a second planar surface;

a device resonator comprising at least one wound conductor disposed on the first planar surface; and

a second plurality of magnetic material pieces in a second plane, wherein at least one of the second plurality of magnetic material pieces overlaps at least one of the first plurality of magnetic material pieces;

wherein a separation between the first and second planes is less than 2 mm; and

wherein the first and second pluralities of magnetic material pieces form a low-reluctance pathway, relative to air, for magnetic flux received by the device resonator.

2. The wireless power device of claim 1 wherein the separation between the first and second planes is less than 0.5 mm.

3. The wireless power device of claim 2 wherein a coupling k between the device resonator and the source resonator is at least 5% greater than the coupling k that would occur between the device resonator and the source resonator in absence of the second plurality of magnetic material pieces.

4. The wireless power device of claim 2 wherein a coupling k between the device resonator and the source resonator is at least 10% greater than the coupling k that would occur between the device resonator and the source resonator in absence of the second plurality of magnetic material pieces.

5. The wireless power device of claim 1 wherein the separation between the first and second planes is uniform.

6. The wireless power device of claim 1 wherein the separation is maintained using a plastic spacer between the first plurality and the second plurality of magnetic material pieces.

7. The wireless power device of claim 1 wherein an overlap between the at least one of the second plurality of magnetic material pieces and the at least one of the first plurality of magnetic material pieces is equal to or greater than 8 mm.

8. The wireless power device of claim 1 wherein an overlap between the at least one of the second plurality of magnetic material pieces and the at least one of the first plurality of magnetic material pieces is within a factor of 10 of a thickness of the first plurality of magnetic material pieces or the second plurality of magnetic material pieces.

9. The wireless power device of claim 5 wherein the first plurality of magnetic material pieces each have a thickness between and including 5 mm to 8 mm.

10. The wireless power device of claim 5 wherein the second plurality of magnetic material pieces each have a thickness between and including 2 mm to 5 mm.

11. The wireless power device of claim 1 wherein a coupling k between the device resonator and the source resonator is at least 5% greater than the coupling k that would occur between the device resonator and the source resonator in absence of the second plurality of magnetic material pieces.

12. The wireless power device of claim 1 wherein a coupling k between the device resonator and the source resonator is at least 10% greater than the coupling k that would occur between the device resonator and the source resonator in absence of the second plurality of magnetic material pieces.

13. The wireless power device of claim 1 wherein a gap in the second plurality of pieces near a center of the at least one wound conductor is 0.5 mm or greater.

14. The wireless power device of claim 1 wherein the at least one conductor is wound in the second plane.

15. The wireless power device of claim 1 further comprising a capacitor network coupled to the at least one wound conductor is positioned under the second plurality of magnetic material pieces.

16. The wireless power device of claim 15 further comprising a conductor piece positioned between the second plurality of magnetic material pieces and the capacitor network.

17. The wireless power device of claim 1 further comprising an aluminum shield positioned adjacent to the first plurality of magnetic material pieces opposite the at least one conductor.

18. The wireless power device of claim 17 wherein the aluminum shield is attached to an underside of a vehicle.