Wireless power transfer systems with shaped magnetic components
First Claim
1. An apparatus for wireless power transfer, the apparatus comprising:
- a coil formed of a conductive material and comprising a plurality of loops, wherein the plurality of loops defines an internal region of the coil that extends along a coil axis; and
a magnetic component, wherein the magnetic component is disposed in the internal region and extends in a first direction parallel to the coil axis and in a second direction perpendicular to the coil axis,wherein a maximum dimension of the magnetic component measured in the second direction varies along the first direction;
wherein a plurality of magnetic elements are joined to form the magnetic component and the plurality of magnetic elements are positioned in a row that extends in a direction parallel to the second direction; and
wherein one or more edges of the magnetic component have a stepped profile.
1 Assignment
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Accused Products

Abstract
In a first aspect, the disclosure features apparatuses for wireless power transfer, the apparatuses including a coil formed of a conductive material. The coil includes a plurality of loops, where the plurality of loops defines an internal region of the coil that extends along a coil axis. The apparatuses include a magnetic component, where the magnetic component is disposed in the internal region and extends in a first direction parallel to the coil axis and in a second direction perpendicular to the coil axis. A maximum dimension of the magnetic component measured in the second direction varies along the first direction.
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17 Claims
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1. An apparatus for wireless power transfer, the apparatus comprising:
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a coil formed of a conductive material and comprising a plurality of loops, wherein the plurality of loops defines an internal region of the coil that extends along a coil axis; and a magnetic component, wherein the magnetic component is disposed in the internal region and extends in a first direction parallel to the coil axis and in a second direction perpendicular to the coil axis, wherein a maximum dimension of the magnetic component measured in the second direction varies along the first direction; wherein a plurality of magnetic elements are joined to form the magnetic component and the plurality of magnetic elements are positioned in a row that extends in a direction parallel to the second direction; and wherein one or more edges of the magnetic component have a stepped profile. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9)
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10. An apparatus for wireless power transfer, the apparatus comprising:
-
a coil formed of a conductive material and comprising a plurality of loops, wherein the plurality of loops defines an internal region of the coil that extends along a coil axis; and a magnetic component, wherein the magnetic component is disposed in the internal region and extends in a first direction parallel to the coil axis and in a second direction perpendicular to the coil axis, wherein a maximum dimension of the magnetic component measured in the second direction varies along the first direction; and wherein the magnetic component has one of an oval shape, a square shape, a hexagonal shape, and a bowtie shape. - View Dependent Claims (11, 12, 13)
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14. An apparatus for wireless power transfer, the apparatus comprising:
-
a coil formed of a conductive material and comprising a plurality of loops, wherein the plurality of loops defines an internal region of the coil that extends along a coil axis; and a magnetic component, wherein the magnetic component is disposed in the internal region and extends in a first direction parallel to the coil axis and in a second direction perpendicular to the coil axis, wherein a maximum dimension of the magnetic component measured in the second direction varies along the first direction; and wherein at least some of the plurality of loops have different diameters, and the diameters of the plurality of loops vary based on positions of each of the loops relative to edges of the magnetic component.
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15. An apparatus for wireless power transfer, the apparatus comprising:
-
a coil formed of a conductive material and comprising a plurality of loops, wherein the plurality of loops defines an internal region of the coil that extends along a coil axis; and a magnetic component, wherein the magnetic component is disposed in the internal region and extends in a first direction parallel to the coil axis and in a second direction perpendicular to the coil axis, wherein a maximum dimension of the magnetic component measured in the second direction varies along the first direction; wherein a plurality of magnetic elements are joined to form the magnetic component and the plurality of magnetic elements are positioned in a row that extends in a direction parallel to the second direction; and wherein each one of the plurality of magnetic elements has a length measured in a direction parallel to the first direction, and at least two magnetic elements have different lengths.
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16. An apparatus for wireless power transfer, the apparatus comprising:
-
a coil formed of a conductive material and comprising a plurality of loops, wherein the plurality of loops defines an internal region of the coil that extends along a coil axis; and a magnetic component, wherein the magnetic component is disposed in the internal region and extends in a first direction parallel to the coil axis and in a second direction perpendicular to the coil axis, wherein a maximum dimension of the magnetic component measured in the second direction varies along the first direction; wherein a plurality of magnetic elements are joined to form the magnetic component and the plurality of magnetic elements are positioned in a row that extends in a direction parallel to the second direction; wherein one or more edges of the magnetic component have a smooth linear profile; and wherein one of; the magnetic elements are arranged such that a magnetic element with a longest length is positioned at a center of the row, and a magnetic element with a shortest length is positioned at an end of the row;
orthe magnetic elements are arranged such that a magnetic element with a longest length is positioned at an end of the row, and a magnetic element with a shortest length is positioned at a center of the row.
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-
17. An apparatus for wireless power transfer, the apparatus comprising:
-
a coil formed of a conductive material and comprising a plurality of loops, wherein the plurality of loops defines an internal region of the coil that extends along a coil axis; and a magnetic component, wherein the magnetic component is disposed in the internal region and extends in a first direction parallel to the coil axis and in a second direction perpendicular to the coil axis, wherein a maximum dimension of the magnetic component measured in the second direction varies along the first direction; wherein a plurality of magnetic elements are joined to form the magnetic component and the plurality of magnetic elements are positioned in a row that extends in a direction parallel to the second direction; and wherein the plurality of magnetic elements are symmetrically arranged with respect to the coil axis.
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1 Specification
This application claims priority under 35 U.S.C. §120 to U.S. Provisional Patent Application No. 61/980,711, filed on Apr. 17, 2014, the entire contents of which are incorporated herein by reference.
This disclosure relates to wireless power transfer systems and methods.
Energy can be transferred from a power source to a receiving device using a variety of known techniques such as radiative (far-field) techniques. For example, radiative techniques using low-directionality antennas can transfer a small portion of the supplied radiated power, namely, that portion in the direction of, and overlapping with, the receiving device used for pick up. In such methods, much—even most—of the energy is radiated away in directions other than the direction of the receiving device, and typically the transferred energy is insufficient to power or charge the receiving device. In another example of radiative techniques, directional antennas are used to confine and preferentially direct the radiated energy towards the receiving device. In this case, an uninterruptible line-of-sight and potentially complicated tracking and steering mechanisms are used.
Another approach to energy transfer is to use non-radiative (near-field) techniques. For example, techniques known as traditional induction schemes do not (intentionally) radiate power, but use an oscillating current passing through a primary coil, to generate an oscillating magnetic near-field that induces currents in a nearby receiving or secondary coil. Traditional induction schemes can transfer modest to large amounts of power over very short distances. In these schemes, the offset tolerances between the power source and the receiving device are very small. Electric transformers and proximity chargers, for example, typically use traditional induction schemes.
This disclosure is related to wireless transfer of power from a power transmitting apparatus to a power receiving apparatus.
In a first aspect, the disclosure features apparatuses for wireless power transfer, the apparatuses including a coil formed of a conductive material. The coil includes a plurality of loops, where the plurality of loops defines an internal region of the coil that extends along a coil axis. The apparatuses includes a magnetic component, where the magnetic component is disposed in the internal region and extends in a first direction parallel to the coil axis and in a second direction perpendicular to the coil axis. A maximum dimension of the magnetic component measured in the second direction varies along the first direction.
Embodiments of the apparatuses can include any one or more of the following features.
The magnetic component can have an anisotropic magnetic permeability.
A plurality of magnetic elements can be joined to form the magnetic component, where the plurality of magnetic elements can be positioned in a row that extends in a direction parallel to the second direction. During operation of the apparatuses an average magnetic field generated by the coil at a given time in the magnetic component can be oriented along a direction different from the second direction.
An edge of the magnetic component can have a stepped profile. Each of the each of the edges of the magnetic component can have a stepped profile.
An edge of the magnetic component has a smooth profile. Each of the edges of the magnetic component can have a smooth profile. An edge of the magnetic component can have a smooth linear profile. Each of the edges of the magnetic component can have a smooth linear profile. An edge of the magnetic component can have a smooth curved profile. Each of the edges of the magnetic component can have a smooth curved profile.
The magnetic component can have an oval shape. The magnetic component can have a square shape. The magnetic component can have a hexagonal shape. The magnetic component can have a bowtie shape.
Each of the plurality of loops can have the same diameter.
The plurality of loops can have different diameters. The diameters of the plurality of loops can vary based on positions of each of the loops relative to edges of the magnetic component. The plurality of loops can have diameters that conform to a shape of the magnetic component.
The average magnetic field generated by the coil at the given time in the magnetic component can be oriented in a direction parallel to the first direction. Each one of the plurality of magnetic elements can have a length measured in a direction parallel to the first direction, and at least two magnetic elements can have different lengths.
The magnetic elements can be arranged such that a magnetic element with a longest length is positioned at a center of the row, and a magnetic element with a shortest length is positioned at an end of the row. The magnetic elements can be arranged such that a magnetic element with a longest length is positioned at an end of the row, and a magnetic element with a shortest length is positioned at a center of the row.
The plurality of magnetic elements can be symmetrically arranged with respect to the coil axis. The plurality of magnetic elements can include at least 10 magnetic elements.
Each one of the plurality of magnetic elements can contact adjacent magnetic elements within the row.
Each one of the plurality of magnetic elements can be connected to adjacent magnetic elements within the row by a dielectric material which can include an adhesive.
During operation, the apparatus can be configured to wirelessly transfer power to, or receive power from, another coil. During operation, the apparatus can be configured to transfer power to an additional coil at an operating frequency within a range of one of: 85 kHz or less, and between about 80 kHz and about 145 kHz. During operation, the apparatus can be configured to transfer power from the coil to an additional coil at 3.3 kW or higher. During operation of the apparatus, a magnetic field can be generated when the coil is driven, the magnetic field having a magnetic flux density that varies in a range from about 10 mT to about 1000 mT.
The magnetic component can include a magnetic alloy including Fe. For example, the magnetic component can include an alloy of Fe, Cu, Nb, Si and B. The magnetic component can include an alloy of Fe, Co, Zr, B and Cu. The magnetic component can include an alloy of Fe, Co, Cu, Nb, Si and B.
In another aspect, the disclosure features methods for wirelessly transferring power using apparatuses, the methods including: generating a magnetic field using a first coil, and positioning the first coil relative to a second coil so that power is transferred by the magnetic field from the first coil to the second coil. The first coil is formed of a conductive material and includes a plurality of loops, where the plurality of loops defining an internal region of the coil that extends along a coil axis. A magnetic component is disposed in the internal region and extending in a first direction parallel to the coil axis and in a second direction perpendicular to the coil axis, and a maximum dimension of the magnetic component measured in the second direction varies along the first direction.
Embodiments of the methods can include any one or more of the following features.
The methods can include transferring power from the first coil to the second coil at an operating frequency of 85 kHz or less.
The methods can include transferring power from the first coil to the second coil at an operating frequency of between about 80 kHz and about 145 kHz.
The transferring power from the first coil to the second coil can be 3.3 kW or higher. The magnetic field can have a magnetic flux density that varies in a range from about 10 mT to about 1000 mT.
Embodiments of the apparatuses and methods can also include any other features disclosed herein, including features disclosed in connection with other apparatuses and methods, in any combination as appropriate.
In this disclosure, “wireless energy transfer” from one coil (e.g., resonator coil) to another coil (e.g., another resonator coil) refers to transferring energy to do useful work (e.g., electrical work, mechanical work) such as powering electronic devices, vehicles, lighting a light bulb or charging batteries. Similarly, “wireless power transfer” from one coil (e.g., resonator coil) to another resonator (e.g., another resonator coil) refers to transferring power to do useful work (e.g., electrical work, mechanical work) such as powering electronic devices, vehicles, lighting a light bulb or charging batteries. Both wireless energy transfer and wireless power transfer refer to the transfer (or equivalently, the transmission) of energy to provide operating power that would otherwise be provided through a wired connection to a power source, such as a connection to a main voltage source. Accordingly, with the above understanding, the expressions “wireless energy transfer” and “wireless power transfer” are used interchangeably in this disclosure. It is also understood that, “wireless power transfer” and “wireless energy transfer” can be accompanied by the transfer of information; that is, information can be transferred via an electromagnetic signal along with the energy or power to do useful work.
Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this disclosure belongs. In case of conflict with publications, patent applications, patents, and other references mentioned or incorporated herein by reference, the present disclosure, including definitions, will control. Any of the features described above may be used, alone or in combination, without departing from the scope of this disclosure. Other features, objects, and advantages of the systems and methods disclosed herein will be apparent from the following detailed description and figures.
Introduction
A wireless power transfer system can include a power transmitting apparatus which is configured to wirelessly transmit power to a power receiving apparatus. In some embodiments, the power transmitting apparatus can include a source coil which generates oscillating fields (e.g., electric, magnetic fields) due to currents oscillating within the source coil. The generated oscillating fields can couple to the power receiving apparatus and provide power to the power receiving apparatus through the coupling. To achieve coupling, the power receiving apparatus typically includes a receiver coil. The oscillating fields generated by the source coil can induce oscillating currents within the receiver coil. In some embodiments, either or both of the source and receiver coils can be resonant. In some other embodiments, either or both of the source and receiver coils can be non-resonant so that power transfer is achieved through non-resonant coupling.
In some embodiments, a wireless power transfer system can utilize a source resonator to wirelessly transmit power to a receiver resonator. For example, a power transmitting apparatus of the system can include the source resonator, which has a source coil, and a power receiving apparatus of the system can include the receiver resonator, which has a receiver coil. Power can be wirelessly transferred between the source resonator and the receiver resonator. In certain embodiments, the wireless power transfer can be extended by multiple source resonators and/or multiple device resonators and/or multiple intermediate (also referred as “repeater” or “repeating”) resonators.
In similar fashion, power receiving apparatus 104 is coupled to a device 108 through a coupling 107. Coupling 107 can be a direct electrical connection or a non-contact inductive coupling. In some embodiments, coupling 107 can include an impedance matching network, as described above.
In general, device 108 receives power from power receiving apparatus 104. Device 108 then uses the power to do useful work. In some embodiments, for example, device 108 is a battery charger that charges depleted batteries (e.g., car batteries). In certain embodiments, device 108 is a lighting device and uses the power to illuminate one or more light sources. In some embodiments, device 108 is an electronic device such as a communication device (e.g., a mobile telephone) or a display. In some embodiments, device 108 is a medical device which can be implanted in a patient.
During operation, power transmitting apparatus 102 is configured to wirelessly transmit power to power receiving apparatus 104. In some embodiments, power transmitting apparatus 102 can include a source coil, which can generate oscillating fields (e.g., electric, magnetic fields) when electrical currents oscillate within the source coil. The generated oscillating fields can couple to power receiving apparatus 104 and provide power to the power receiving apparatus through the coupling. To achieve coupling between power transmitting apparatus 102 and power receiving apparatus 104, the power receiving apparatus can include a receiver coil. The oscillating fields can induce oscillating currents within the receiver coil. In some embodiments, either or both of the source and receiver coils can be resonant. In certain embodiments, either or both of the source and receiver coils can be non-resonant so that the power transfer is achieved through non-resonant coupling.
In certain embodiments, the system 100 can include a power repeating apparatus (not shown in
System 100 can include an electronic controller 103 configured to control the power transfer in the system 100, for example, by directing electrical currents through coils of the system 100. In some embodiments, the electronic controller 103 can tune resonant frequencies of resonators included in the system 100, through coupling 109. The electronic controller 103 can be coupled to one or more elements of the system 100 in various configurations. For example, the electronic controller 103 can be only coupled to power source 106. The electronic controller 103 can be coupled to power source 106 and power transmitting apparatus 102. The electronic controller 103 can be only coupled to power transmitting apparatus 102. In some embodiments, coupling 109 is a direct connection. In certain embodiments, coupling 109 is a wireless communication (e.g., radio-frequency, Bluetooth communication). The coupling 109 between the electronic controller 103 can depend on respective one or more elements of the system 100. For example, the electronic controller 103 can be directly connected to power source 106 while wirelessly communicating with power receiving apparatus 104.
In some embodiments, the electronic controller 103 can configure the power source 106 to provide power to the power transmitting apparatus 102. For example, the electronic controller 103 can increase the power output of the power source 106 by sending a higher drive current to a coil in the power transmitting apparatus 102. The power output can be at an operating frequency, which is used to generate oscillating fields by the power transmitting apparatus 102.
In certain embodiments, the electronic controller 103 can tune a resonant frequency of a resonator in the power transmitting apparatus 102 and/or a resonant frequency of a resonator in the power receiving apparatus 104. By tuning resonant frequencies of resonators relative to the operating frequency of the power output of the power source 106, the efficiency of power transfer from the power source 106 to the device 108 can be controlled. For example, the electronic controller 103 can tune the resonant frequencies to be substantially the same (e.g., within 0.5%, within 1%, within 2%) to the operating frequency to increase the efficiency of power transfer. The electronic controller 103 can tune the resonant frequencies by adjusting capacitance values of respective resonators. To achieve this, for example, the electronic controller 103 can adjust a capacitance of a capacitor connected to a coil in a resonator. The adjustment can be based on the electronic controller 103'"'"'s measurement of the resonant frequency or based on wireless communication signal from the apparatuses 102 and 104. In certain embodiments, the electronic controller 103 can tune the operating frequency to be substantially the same (e.g., within 0.5%, within 1%, within 2%) to the resonant frequencies of the resonators.
In some embodiments, the electronic controller 103 can control an impedance matching network in the system 100 to optimize or de-tune impedance matching conditions in the system 100, and thereby control the efficiency of power transfer. For example, the electronic controller 103 can tune capacitance of capacitors or networks of capacitors included in the impedance matching network connected between power transmitting apparatus 102 and power source 106. The optimum impedance conditions can be calculated internally by the electronic controller 103 or can be received from an external device.
The power transmitting apparatus 200 can include a shield 206 (e.g., a sheet of conductive material) positioned between coil 204 and a lossy object 208. Shield 206, which is typically formed of a conductive material, shields magnetic fields generated by coil 204 from lossy object 208 (e.g., lossy steel object). For example, the shield 206 can reduce aberrant coupling of magnetic fields to lossy object 208 by guiding magnetic field lines away from the lossy object 208.
In some embodiments, shield 206 can include two flaps 207 which are bent down ends of the conductor shield 206. Flaps 207 do not add to the overall length 209 of the conductor shield 206, but can improve the shielding effect of the conductor shield 206 by deflecting and guiding magnetic field lines downwards, and reducing field interactions with lossy object 208. This configuration can increase the effectiveness of the shield 206 without increasing its length 209. Note that a power receiving apparatus and or a power repeating apparatus can use the structure shown in
Nanocrystalline Magnetic Materials
Magnetic components can include magnetic materials. During operation, the temperature of a magnetic component within an apparatus can increase due to a variety of factors. For example, in vehicle battery charging applications, magnetic components of large areal size (e.g., 30 cm×30 cm) are useful for transferring high power of 1 kW or more (e.g., 2 kW or more, 3 kW or more, 5 kW or more, 6 kW or more). In some embodiments, if a single piece of magnetic component of the required size is available, it may be preferable to use the single piece of material. In some embodiments, it can be difficult and/or expensive to manufacture a monolithic piece of magnetic component from ferrite materials such as manganese-zinc (MnZn) and/or nickel-zinc (NiZn) which may be brittle and costly for producing large areal sizes. One solution to this problem is to fabricate ferrite materials in pieces of smaller areal size (e.g., 5 cm×5 cm), and then join several pieces together to form a larger piece of magnetic component. However, when multiple pieces of ferrite material are joined together, irregularities at edges of the pieces can lead to “magnetic field hot spots,” where magnetic fields are locally concentrated at the irregularities. Such hot spots can damage the magnetic component due to localized heating, and/or reduce a quality factor of the apparatus.
Referring back to
In this disclosure an “average magnetic field” of a magnetic component at a given time refers to the magnetic field integrated over the total volume of all magnetic elements in the magnetic component at the given time.
Furthermore, the magnetic fields generated in the gap 422 oscillate in the B-direction. Accordingly, the magnetic fields generated in the gap 422 oscillate in a perpendicular direction to an interface 432 between the magnetic element 410 and the dielectric material 420 and an interface 434 between the magnetic element 416 and the dielectric material 420.
As discussed briefly above, magnetic field hot spots can arise within gap 422 due to imperfections in magnetic elements 410, 412, 414, and 416, and these hot spots can lead to local heating of the magnetic component in the vicinity of the hot spots.
As shown in
For example, magnetic fields 520 depicted as dashed arrows within region 510 can concentrate on the peak 512. Concentrated field regions (e.g., region 510) can lead to increased heating if the magnetic flux densities are high enough, which can cause damage to, and even structural breakdown of, the magnetic component, which in turn can cause deteriorated power transfer efficiency provided by the power transmitting apparatus 400.
Furthermore, magnetic field hot spots can become more pronounced when the distance between the interfaces 432 and 434 is decreased. The distance between interfaces 432 and 434 can be reduced, for example, when elements 410 and 416 are joined together more closely to achieve a more compact arrangement of the magnetic elements 410 and 416. Polishing the interfaces can, in certain embodiments, assist in reducing the extent of irregularities at the surfaces, but it is difficult to fully ameliorate surface irregularities that lead to magnetic hot spots through polishing alone.
The effects of heating and, more generally, temperature variations within magnetic components, can be addressed by using alternative magnetic components. In particular, alternative magnetic components can be attractive if they can be fabricated in larger sizes. Then, the magnetic component in an apparatus can be implemented as a single piece of material or formed from a relatively smaller number of magnetic elements, thereby reducing local heating due to imperfections in the edges of the smaller tiles of magnetic component.
Magnetic materials used in magnetic components can have magnetic properties that make them advantageous for use in environments where temperature variations such as heating can occur. For conventional magnetic materials (e.g., MnZn ferrites), the magnetic permeability typically depends on the temperature and magnetic field density within the magnetic materials. Thus, changes in the temperature and magnetic field density can lead to different magnetic permeability values of the magnetic component which can alter the impedance matching conditions of the system, and can thereby reduce the power transfer efficiency of the system.
However, certain alternative magnetic components can include magnetic materials with magnetic properties that are relatively constant over a range of temperatures and power transfer rates compared to, for example, MnZn ferrites. Moreover, these magnetic materials typically have strong stress resilience compared to MnZn and other ferrites and are therefore mechanically stronger than MnZn ferrites. By using such magnetic materials, variations in impedance matching conditions can be reduced, and maintenance costs associated with of wireless power transfer systems can also be reduced. Moreover, such magnetic materials may transfer more power per weight than magnetic materials as MnZn ferrites.
As explained above, local heating can arise from magnetic field hot spots that are attributable to imperfections in the magnetic elements that are joined to form a magnetic component. To form large area magnetic components from conventional ferrite-based materials, many such elements may be used, because high quality ferrite-based materials are typically difficult to fabricate in large sizes due to their brittleness.
In contrast, nanocrystalline magnetic materials can typically be fabricated in relatively large sizes. Consequently, a magnetic component can be fabricated from magnetic elements formed from nanocrystalline magnetic materials, arranged so that substantially no gaps that lead to magnetic field hot spots are present between the elements. By eliminating such gaps, local heating due to magnetic field hot spots can be reduced or even eliminated.
As an example, consider an apparatus utilizing a large magnetic component having dimensions of 30 cm×30 cm. Magnetic elements formed of a nanocrystalline magnetic material and having at least one dimension (e.g., a length) of 30 cm can be fabricated, and then joined to form the magnetic component, leaving no gaps between the elements that lead to (e.g., no gaps such as gap 422) field concentration and associated excessive localized heating. In general, nanocrystalline magnetic materials can be used to form magnetic elements having at least one dimension that extends a large length (e.g., 30 cm or more, 40 cm or more, 50 cm or more). The nanocrystalline magnetic materials can be more robust than ferrite material such as MnZn or NiZn.
A variety of different nanocrystalline magnetic materials can be used in the systems disclosed herein. For example, in some embodiments, nanocrystalline magnetic materials can be nanocrystalline alloys formed on a basis of Fe, Si and B with additions of Nb and Cu. Nanocrystalline magnetic materials can be an alloy of Fe, Cu, Nb, Si and B (e.g., Fe73.5Cu1Nb3Si15.5B7). In some embodiments, nanocrystalline magnetic materials can be an alloy of Fe, Co, Zr, B and Cu. In certain embodiments, nanocrystalline magnetic materials can be an alloy of Fe, Si, B, Cu and Nb. In certain embodiments, nanocrystalline magnetic materials can be an alloy of Fe, Co, Cu, Nb, Si and B. The nanocrystalline magnetic material can include an alloy based on Fe. For example, the alloy can be a FeSiB alloy.
Nanocrystalline magnetic materials can include NANOPERM® or FINEMET®. In certain embodiments, amorphous cobalt- and iron-based alloys can be used as a magnetic component. For example, NANOPERM® available from MAGNETEC is a rapidly quenched iron based alloy. The alloy composition is Fe73.5Cu1Nb3Si15.5B7. FINEMET® is available from Hitachi. FINEMET® includes an alloy of Fe, Si, B and small amounts of Cu and Nb. By applying heat treatment to the alloy at higher temperatures than its crystalline temperature, the alloy can form nanocrystalline structures.
In certain embodiments, amorphous cobalt-based alloys or amorphous iron-based alloys can be used as a magnetic component. Such alloys may have the advantages described in relation to nanocrystalline magnetic materials over ferrites such as MnZn and NiZn.
Characteristics of nanocrystalline magnetic materials and MnZn ferrites can be compared by analyzing quantities that relate to their performance for wireless power transfer at different operating frequencies. In the following discussion, quantities such as their magnetic permeabilities, and the reactive power (Px) of an apparatus which utilizes these materials are described. Some of these quantities are measured to compare the characteristics of certain nanocrystalline magnetic materials and MnZn ferrites.
For a wireless power transfer system utilizing a source resonator configured to transfer power to a receiver resonator, the figure-of-merit (U) can be expressed by U=κ/√{square root over (Γ1Γ2)}, where κ is the coupling rate between the source and receiver resonators. The source resonator can have an angular resonant frequency ω1 and a Q-factor Q1=ω1/(2 Γ1), where Γ1 is related to the intrinsic loss of the source resonator. The receiver resonator can have an angular resonant frequency ω2 and a Q-factor Q2=ω2/(2 Γ2), where Γ2 is related to the intrinsic loss of the receiver resonator. For a given geometry of a resonator, and assuming a constant overall figure-of-merit (U) and power transfer Pw to a load in the system, the reactive power Px may be constant, which is expressed according to Eq. (1) shown below:
where B is a magnetic field at a given location and μ0 is the vacuum permeability.
In some embodiments, a power transmitting apparatus of the system can include a magnetic component. (Similarly, a power receiving apparatus or a power repeating apparatus of the system can include a magnetic component.) The magnetic component can have a magnetic permeability μ that can be expressed into real and imaginary parts according to Eq. (2) shown below:
μ=μs′+iμs″=μr+iμi. (2)
μs′=μr is the real part and μs″=μi is the imaginary part. The magnetic permeability μ can also be expressed according to Eq. (3) shown below:
Assuming the absence of nonlinearity of the magnetic component, Qμ of the magnetic component can be expressed according to Eq. (4) shown below:
Qμ≈g×μp″, (4)
where g is a dimensionless factor depending on the geometry of the source resonator. Qμ can be considered as the quality factor contributed by the magnetic component (described later). μp″ is the imaginary part of the parallel magnetic permeability as shown in Eq. (3). A plot of reactive power PX versus μp″ can provide a comparison of the performance of different magnetic components at different frequencies.
Certain nanocrystalline magnetic materials can be advantageous relative to N95® for use in high power transfer because for such materials, the imaginary part of the parallel magnetic permeability (μp″) at high reactive power (Px) is higher than for N95®, which leads to higher Qμ according to Eq. (4). To illustrate this,
Curve 1202 corresponds to N95® at 80 kHz; curve 1204 corresponds to N95® at 145 kHz; curve 1206 corresponds to M-669 at 80 kHz; curve 1208 corresponds to M-679 at 80 kHz; and curve 1210 corresponds to M-449 at 80 kHz. Similar to the curves shown in
Moreover, plot 1200 shows that nanocrystalline magnetic materials can have higher imaginary components of the parallel magnetic permeability (μp″) than N95® at higher reactive powers (PX). For example, M-669 and M-679 have higher μp″ than N95® for Px larger than 106 kW/m3. Accordingly, in some applications such as high power transfer, nanocrystalline magnetic materials can be advantageous relative to N95® because of the nanocrystalline magnetic materials'"'"' higher imaginary component of the parallel magnetic permeability (μp″) at high reactive power (Px).
At higher power transfer, nanocrystalline materials can be less lossy than N95®. In particular, nanocrystalline magnetic materials with reduced power dissipation can provide important advantages in applications involving the transfer high power of 1 kW or more (e.g., 2 kW or more, 3 kW or more, 5 kW or more, 6 kW or more). For example, the high power transfer can be about 3.3 kW or more (e.g., 6.6 kW or more).
On the other hand, the curves for the nanocrystalline materials are relatively flatter. For example, curves 1246 and 1248 show a substantially flat dependence (e.g., variations within 10%) in the range of values between 0.5×102 mT and 0.5×103 mT of peak magnetic flux (Bpk). As discussed above, the substantially flat dependence of the real part of the magnetic permeability (μr) as a function of peak magnetic flux (Bpk) can be advantageous because impedance matching conditions typically depend on the real part of magnetic permeability (μr); by using a material with a relatively constant real component of magnetic permeability, tuning of impedance matching conditions as the applied power varies can be reduced. As an example, curve 1246 shows a substantially flat dependence (e.g., variations within 5%) for values of the peak magnetic flux (Bpk) that vary by a factor of 10. Changes of a factor of 10 of peak magnetic flux (Bpk) can correspond to changes of a factor of 100 in power transferred. The impedance of an apparatus that includes a magnetic component formed from the M-669 nanocrystalline material may change by an amount smaller than 5% when the power transferred by the apparatus increases by a factor of about 100.
One or more of the nanocrystalline magnetic materials disclosed herein can be used to form magnetic elements, which can in turn be combined to form a magnetic component. The left-side of
Nanocrystalline magnetic materials can be formed in the shape of a thin ribbon. In some processes, the nanocrystalline magnetic material can be initially in powder form and then be crystallized by annealing at a high temperature (e.g., between 400-500° C., between 500-600° C.). Then, during the annealing step, the powder can be processed to form ribbons having a length of 15 cm or more (e.g., 20 cm or more, 30 cm or more, 40 cm or more, 50 cm or more, 100 cm or more, 200 cm or more). The ribbon can be cut into pieces to form one or more magnetic elements 602. Using such techniques, the length 630, thickness 634 and height 632 of the magnetic element 602 can be controlled during the manufacturing process. Because the ribbon can be long, the resulting length 630 of the magnetic element 602 can be 15 cm or more (e.g., 20 cm or more, 30 cm or more, 40 cm or more, 50 cm or more).
As discussed above, a plurality of such magnetic elements 602 can be used to form a magnetic component with large areal size and without the gaps that lead to hot spots in tiled magnetic components. To eliminate gaps in which hot spots form (e.g., gaps where magnetic fields oscillate perpendicular to interfaces of the gaps), a plurality of joined magnetic elements 602 can be oriented such that magnetic field oscillations occur in a direction that is nominally within the plane of the interfaces between the magnetic elements 602. As a result, the extent to which hot spots form at the interfaces is significantly reduced, and heating or damage to the magnetic component arising from magnetic field hot spots can be reduced or eliminated.
The center diagram of
In this arrangement, there is no gap as described in relation to
Although six magnetic elements 602 are in the magnetic component 402 of the center diagram in
In some embodiments, the absence of or the reduced number of gaps can lead to a tighter tolerance on an apparatus'"'"' self-inductance. The tighter tolerance can mean that apparatuses can be mass-produced, with a small range of variations in properties between different apparatuses. By mass-producing apparatuses with small variations in properties, wireless power transfer systems can be constructed and operate more reproducibly, with less fine-tuning during assembly, leading to reduced manufacturing costs.
In this disclosure, an “outer boundary” of a cross-section refers to a perimeter defined by magnetic elements and dielectric materials (if any) of a magnetic component in the plane of the cross-section. The magnetic component 402 shown in the center of
A coil 604 formed by at least one loop, or a plurality of loops, as shown, of conductive material is wrapped around the magnetic component 402; the loops define a coil axis that is parallel to axial direction 441. Magnetic fields generated by the coil 604 oscillate substantially along the axial direction 441. An average magnetic field of the magnetic component 402 at a given time is oriented along the axial direction 441. In certain embodiments, an angle between the direction of the average magnetic field at a given time and axial direction 441 is 10° or less (e.g., 5° or less, 3° or less, 1° or less).
As in
Magnetic elements 602 forming the magnetic components 402 described in
Contoured Magnetic Components
Spatially inhomogeneous local heating of a magnetic component can also occur for reasons other than magnetic hot spot formation in gaps between magnetic elements that form the magnetic component. For example, even though in
To address the concentration of magnetic fields at edges 650, the lengths of magnetic elements 602 near edges 650 can be reduced to increase the magnetic reluctance at the edges. As a result, the magnetic reluctance of different magnetic elements 602 of the magnetic component 402 can be controlled, such that the reluctances of different elements are similar to one another. Producing a more uniform magnetic reluctance distribution in magnetic component 402 in this manner leads to the generation of a more uniform magnetic field distribution within the magnetic component 402.
Non-uniform magnetic field distributions within the magnetic component lead to the formation of hot spots, because power is dissipated locally in proportion to the square of the magnetic field amplitude. Moreover, a non-uniform magnetic field distribution increases the loss coefficient of the magnetic component. Both of these effects lead to a reduced quality factor on an apparatus that includes the magnetic component, and can even cause the magnetic component to saturate at lower power levels.
However, these effects can be mitigated by generating a more uniform magnetic field distribution within the magnetic component, as described above. In particular, because power dissipation varies approximately proportionally to the square of the magnetic field amplitude, for a fixed total magnetic flux through a magnetic component, a configuration with a more uniform field distribution will generally exhibit lower losses—and a higher quality factor—than a configuration with a less uniform field distribution. The effect is analogous to the electrical resistance of an electrical conductor, where decreasing the effective cross-sectional area of the conductor leads to higher resistance, for example, due to the skin effect.
Hot spots that occur at the boundaries of the magnetic component reduce the uniformity of the magnetic fields within the magnetic component, which can lead to material saturation and cause local heating and damage to the magnetic elements 602. In addition, as explained above, certain magnetic properties of the elements, such as the magnetic permeability, typically depend on the temperature and magnetic field density within the elements. Accordingly, changes in the temperature and magnetic field density can lead to different magnetic permeability values of the magnetic component formed from the elements, and of the apparatus that includes the magnetic component, which can alter the impedance matching conditions of the system.
The formation of magnetic hot spots at the boundaries of the magnetic component can be visualized by electromagnetic simulations that calculate magnetic field distributions within the magnetic component.
As shown in
Several approaches can be used to mitigate the heating of the magnetic component by reducing the formation of hot spots at the material'"'"'s boundaries. In particular, one such approach involves varying the lengths of the magnetic elements that form the magnetic component in the direction of the oscillating magnetic fields. For example, groups 620, 621, 622, and 623 shown in
In general, magnetic components with a wide variety of different contour geometries can be produced by using magnetic elements of different lengths and shapes. The performance of magnetic components formed from such magnetic elements can be analyzed using electromagnetic simulations which calculate the magnetic field distribution within the magnetic component. As an example,
A wide variety of different magnetic component geometries can be used to reduce magnetic field hot spot formation at the edges of the material (e.g., proximal to the coil turns).
Coil 604 is wrapped around the magnetic component 402 and extends along axial direction 441. The coil 604 can be formed of a conductive material and can include a plurality of loops defining an internal region that extends along the axial direction 441. The magnetic component 402 is positioned in the internal region and extends in both the axial direction 441 and in a direction 442 perpendicular to the axial direction 441. In this example, the direction 442 is parallel to the x-direction.
In the configuration illustrated in the right-side of
The right-side of
The multiple magnetic elements 602 included in groups 620-624 are arranged in a row extending along the x-direction perpendicular to axial direction 441. Magnetic element 750 with the longest length 630 among the elements 602 is positioned at a center 760 of the row. Magnetic elements 751 and 752 with the shortest lengths 630 among the elements 602 are positioned at ends 761 and 762, respectively, of the row. The magnetic elements 620 are arranged symmetrically with respect to axis 441, which passes through the center 760 of the magnetic component. In this example, the magnetic component has mirror symmetry about center 760.
Compared to the examples shown in
The left-side of
The right-side of
Compared to the examples shown in
In some wireless power transfer applications, it may be advantageous to utilize the orientation of magnetic elements 602 as described in
Group 622 in
For certain applications, the configuration of group 622 in
Generally, in the embodiments disclosed herein, a magnetic component can include magnetic elements which have different lengths, different thicknesses, curved edges, straight edges, and which are joined using a variety of different methods. The magnetic elements can be arranged in a variety of ways so that a coil can generate a uniform distribution of magnetic fields within the magnetic component. By generating a uniform field distribution, the occurrence of hot spots at edges of the magnetic component can be reduced or even eliminated.
The embodiments shown in
In addition to magnetic components having cross-sectional shapes that correspond to diamond shapes (e.g., stepped diamond shapes), magnetic components with other cross-sectional shapes can also be used to achieve more uniform magnetic field distributions within the materials.
The magnetic elements 602 in
Coordinate 690 shows the local coordinate of the magnetic element 802. Other magnetic elements 602 in magnetic component 402 have their own respective curved surfaces so that when they are assembled to form the oval shape of the outer boundary 660 depicted in the left-side view of
In some embodiments, the oval shape can be obtained by polishing the sides of the assembled magnetic elements 602. Alternatively, the oval shape can be obtained by polishing individual magnetic elements 602 before assembling the magnetic component 402 from the elements. In certain embodiments, it may be unnecessary to polish the edges of magnetic elements 602 to have smooth edges. As such, the oval shape of the outer boundary 660 may not have a smooth contour but can have stepped portions defined by the edges of magnetic elements 602.
Generally, the outer boundary 660 can have a wide variety of different curved shapes. For example, in some embodiments, outer boundary 660 or a portion thereof corresponds to a curved shape that can be described by a polynomial function. In some embodiments, the outer boundary 660 or a portion thereof corresponds to a curved shape that can be described by an elliptical function, a circular function, a hyperbolic function, or a parabolic function. In certain embodiments, the outer boundary 660 can have a compound curved shape that includes two or more differently-curved portions. For example, the left-side view of
In some embodiments, outer boundary 660 can include both straight and curved segments, including any of the different straight and curved segments disclosed herein. Moreover, in certain embodiments, outer boundary 660 can have an irregular shape.
In some embodiments, outer boundary 660 can be symmetric. For example, outer boundary 660 can have inversion symmetry about a central point of the magnetic component. As another example, outer boundary 660 can be symmetric with respect to reflection about one or more axes, and/or symmetric with respect to rotation about an axis (e.g., an axis extending through a center of symmetry of the magnetic component in a direction perpendicular to a plane of the magnetic component). In certain embodiments, outer boundary 660 is not symmetric about a particular point or axis.
In some embodiments, the spacing and diameter of the coil 604 can be varied to achieve a more uniform magnetic field distribution within a magnetic component 402, thereby reducing hot spot formation near the edges of the magnetic component. In certain embodiments, apparatus 801 can have its coil 604 wound around magnetic component 402 such that coil 604 conforms to the shape of magnetic component 402 as shown in the right-side of
By way of illustration, on the left-side of
On the other hand, the right-side of
In some embodiments, the coil 604 can be wound directly on and contact the magnetic component 604 without a support structure in between. This approach may allow the apparatus 801 to have a smaller volume and reduced manufacturing costs relative to apparatus 800 for the same size of magnetic component 402. In some other embodiments, the coil 604 can be wound around a support structure (not shown), which conforms to the shape of magnetic component 402 and guides the coil 604 around the magnetic component 402.
Magnetic component 402a in the upper left portion of
Referring back to the upper left portion of
Direction 442 is parallel to the x-direction and is perpendicular to the axial direction 441. The maximum dimension of magnetic component 402a measured in direction 442 varies along the axial direction 441. For example, at location 910, the magnetic component 402 has a maximum dimension 920 measured in the direction 442. At location 911, the magnetic component 402 has a maximum dimension 921 measured in the direction 442. The examples shown in
The upper-right side of
Alternatively, in some embodiments, the outer boundary 660 does not have a smooth contour portion but instead has a stepped profile defined by the edges of magnetic elements 602. A schematic cross-sectional view of such a magnetic component labeled as 402d is shown in the lower-right portion of
The lower-left side portion of