Magnetically permeable structures

• US 9,972,434 B2
• Filed: 10/06/2015
• Issued: 05/15/2018
• Est. Priority Date: 03/20/2012
• Status: Active Grant

• Current Assignee: WiTricity Corporation
• Original Assignee: Qualcomm, Inc.
• Inventors: Keeling, Nicholas Athol, Van Boheemen, Edward, Kissin, Michael Le Gallais, Beaver, Jonathan
• Primary Examiner(s): Barnie, Rexford
• Assistant Examiner(s): Vu, Toan
• Application Number:
  US14/876,511
• Publication Number:
  US 20160027577A1
• Time in Patent Office: 952 Days
• Field of Search: 307104
• CPC Class Codes: H01F 27/022 Encapsulation
• CPC Class Codes: H01F 27/263 Fastening parts of the core together
• 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 41/005 Impregnating or encapsulating insulating of windings H01F41/12
• CPC Class Codes: H01F 41/0206 Manufacturing of magnetic cores by mechanical means magnetic cores per se H01F27/24
• CPC Class Codes: H02J 50/12 of the resonant type
• CPC Class Codes: H02J 50/402 the two or more transmitting or the two or more receiving devices being integrated in the same unit, e.g. power mats with several coils or antennas with several sub-antennas
• CPC Class Codes: H02J 50/60 responsive to the presence of foreign objects, e.g. detection of living beings
• CPC Class Codes: H02J 50/70 involving the reduction of electric, magnetic or electromagnetic leakage fields
• CPC Class Codes: H02J 50/80 involving the exchange of data, concerning supply or distribution of electric power, between transmitting devices and receiving devices
• CPC Class Codes: H02J 50/90 involving detection or optimisation of position, e.g. alignment
• CPC Class Codes: H05K 13/00 Apparatus or processes specially adapted for manufacturing or adjusting assemblages of electric components
• CPC Class Codes: Y10T 29/4902 Electromagnet, transformer or inductor

Abstract

An apparatus, a system and a method for wireless power transfer are disclosed. A method of forming a physical core of a wireless power transfer device includes positioning two or more electromagnetically permeable members adjacent to one another and applying longitudinal pressure to an end of the electromagnetically permeable members, the electromagnetically permeable members at least partially encapsulated in retaining compound. A wireless power transfer device includes a casing in which is housed an induction coil, a plurality of electromagnetically permeable members arranged in a line and a retaining compound.

Claims

1. A method of forming a physical core of a wireless power transfer device, comprising:

positioning two or more electromagnetically permeable members adjacent to one another;

applying longitudinal pressure to a first end of one of the electromagnetically permeable members; and

at least partially encapsulating the electromagnetically permeable members in retaining compound.

2. The method of claim 1, further comprising:

allowing the retaining compound to at least partially set; and

releasing the longitudinal pressure applied to the first end of the one electromagnetically permeable member.

3. The method of claim 1, wherein the step of positioning two or more electromagnetically permeable members includes positioning the two or more electromagnetically permeable members adjacent one another within a wireless power transfer device casing.

4. The method of claim 1, wherein the application of longitudinal pressure is applied by positioning a resilient spring member between the first end of the one electromagnetically permeable member and a first portion of the casing.

5. The method of claim 4, wherein the two or more electromagnetically permeable members are arranged in a line, wherein an additional resilient spring member is positioned between a second end of the two or more electromagnetically permeable members and a second portion of the casing.

15. The method of claim 11, The wireless power transfer device of claim 1, wherein the electromagnetically permeable members and induction coil are housed within a casing.

6. A method of forming a wireless power transfer device, comprising the steps of:

positioning two or more electromagnetically permeable members and an induction coil within a casing;

arranging the electromagnetically permeable members to form a line of electromagnetically permeable members;

positioning the electromagnetically permeable members in electromagnetic association with the induction coil;

applying longitudinal pressure to a first end of the line of electromagnetically permeable members, and

at least partially encapsulating the electromagnetically permeable members in a retaining compound.

7. The method of claim 6, further comprising:

allowing the retaining compound to at least partially set, and

releasing the longitudinal pressure applied to the end of each line of electromagnetically permeable members.

8. The method of claim 6, wherein the step of positioning two or more electromagnetically permeable members includes positioning the two or more electromagnetically permeable members adjacent one another within a wireless power transfer device casing.

9. The method of claim 6, wherein the application of longitudinal pressure is applied by positioning a resilient spring member between the first end of the line of electromagnetically permeable members and a first portion of the casing.

10. The method of claim 9, wherein an additional resilient spring member is positioned between a second end of the line of electromagnetically permeable members and a second portion of the casing.

11. A method of wirelessly transferring power with a wireless power transfer device, the method comprising:

coupling the wireless power transfer device to a magnetic field via an induction coil;

concentrating the magnetic field via a plurality of electromagnetically permeable members placed within the wireless power transfer device; and

transferring power via the magnetic field,

wherein two or more of the electromagnetically permeable members abut one another, wherein the plurality of electromagnetically permeable members are at least partially encapsulated in a retaining compound, and wherein the retaining compound maintains an applied longitudinal pressure between adjacent electromagnetically permeable members.

12. The method of claim 11, wherein the electromagnetically permeable members are arranged in a plurality of substantially parallel lines.

13. The method of claim 12, wherein the plurality of electromagnetically-permeable members are spaced in adjacent parallel lines configured to allow a substantial portion of the magnetic field produced by the induction coil to pass through the parallel lines of electromagnetically permeable members.

14. The method of claim 11, wherein the electromagnetically permeable members include ferrite bars.

16. The method of claim 11, wherein pressure is applied to the two or more abutting electromagnetically permeable members to reduce air gaps between the two or more of the electromagnetically permeable members abutting one another when positioned end to end to form a bar or positioned in a grid.

17. The method of claim 16, wherein the applied pressure is maintained between the two or more of the electromagnetically permeable members abutting one another using an adhesive applied between abutting electromagnetically permeable members.

18. The method of claim 17, wherein the two or more of the electromagnetically permeable members abutting one another are tightly spaced such that their permeability is substantially similar to a permeability of a single electromagnetically permeable member.

19. The method of claim 11, wherein the retaining compound is further configured to maintain a position of the plurality of electromagnetically permeable members.

20. The method of claim 11, wherein the retaining compound is further configured to maintain a spacing of and an orientation of the induction coil.

21. An apparatus for wirelessly transferring power, comprising:

means for housing;

means for coupling the apparatus to a magnetic field;

a plurality of means for concentrating the magnetic field;

means for transferring power via the magnetic field; and

means for encapsulating the concentrating means,

wherein two or more of the concentrating means abut one another and wherein the encapsulating means maintains an applied longitudinal pressure between adjacent concentrating means, and wherein the housing means comprises the coupling means, the plurality of concentrating means, and the encapsulating means.

22. The apparatus of claim 21, wherein the concentrating members are arranged in a plurality of substantially parallel lines.

23. The apparatus of claim 22, wherein spacing between adjacent parallel lines is configured to allow a substantial portion of the magnetic field produced by the coupling means to pass through the parallel lines of concentrating means.

24. The apparatus of claim 21, wherein the concentrating means include ferrite bars.

25. The apparatus of claim 21, wherein the concentrating means and the coupling means are housed within the housing means.

26. The apparatus of claim 21, wherein an applied pressure reduces air gaps between the two or more concentrating means abutting one another when positioned end to end to form a bar or positioned in a grid.

27. The apparatus of claim 26, wherein the applied pressure is maintained between the two or more concentrating means abutting one another via an adhesive applied between the two or more concentrating means.

28. The apparatus of claim 27, wherein the two or more concentrating means abutting one another are tightly spaced such that their permeability is substantially similar to a permeability of a single concentrating means.

29. The apparatus of claim 21, wherein the encapsulating means is further configured to maintain a position of the plurality of concentrating means.

30. The apparatus of claim 21, wherein the encapsulating means is further configured to maintain a spacing of and an orientation of the coupling means.