Wireless power transfer system with extended wireless charging range

Patent metadata

Field	Value
Publication number	US-11271430-B2
Application number	US-201916517058-A
Country	US
Kind code	B2
Filing date	Jul 19, 2019
Priority date	Jul 19, 2019
Publication date	Mar 8, 2022
Grant date	Mar 8, 2022

Abstract

The present application relates to an apparatus which comprises a wireless power transfer (WPT) system. This system comprises features which allow it to transfer more power wirelessly at extended distances than other systems operating in the same frequency range. The system possesses heat dissipation features; these features allow it to operate effectively in elevated-temperature environments, and to transfer power at higher levels and/or greater distances than a typical power-transfer system. The system also might include design features to withstand mechanical shocks, stresses, and impacts for use in a rugged environment. The system can also comprise adaptations to reduce electromagnetic interference (EMI), and can comprise specially shaped components with magnetic/ferrimagnetic properties that enhance performance. Other potential features include power conditioning by combining, within one circuit or one board, multiple elements that protect against excessive current, over-voltage, and/or reverse voltage. Other features might include integration of an antenna and a battery within one module.

First claim

What is claimed is:

1. A wireless power system for transferring power, the wireless power system comprising:
a receiving coil;
one or more receiving electronics electrically connected to the receiving coil;
a transmitting coil assembly comprising:
a magnetic backing;
a magnetic ring that surrounds at least a portion of the magnetic backing;
a magnetic core affixed to a given surface of the magnetic backing, wherein the magnetic backing extends beyond the magnetic core; and
a transmitting coil that surrounds the magnetic core, wherein the transmitting coil is configured to couple to the receiving coil; and

one or more transmitting electronics electrically connected to the transmitting coil, wherein at least one of the one or more transmitting electronics comprises a control system loop that is configured to vary one or more of a frequency, an input voltage, an input current, or a duty cycle,
wherein the wireless power system is configured to maintain uninterrupted operation.

2. The wireless power system of claim 1 , wherein the magnetic backing or magnetic core comprises a ferrimagnetic material.

3. The wireless power system of claim 2 , wherein the ferrimagnetic material is a ferrite.

4. The wireless power system of claim 3 , wherein the ferrite comprises a ceramic compound of a transition metal with oxygen.

5. The wireless power system of claim 3 , wherein the ferrite comprises an iron oxide combined with nickel, zinc, and manganese.

6. The wireless power system of claim 1 , wherein the magnetic backing or magnetic core comprises a magnetic shielding material.

7. The wireless power system of claim 6 , wherein the magnetic shielding material comprises one of a manganese-zinc, a nickel-zinc, a copper-zinc, a magnesium-zinc, or combinations thereof.

8. The wireless power system of claim 1 , wherein an operating frequency of the wireless power system ranges from 25 kHz to 300 kHz.

9. The wireless power system of claim 1 , wherein the transferring power ranges from 1 nW to 30 W.

10. The wireless power system of claim 1 , wherein a coil-to-coil distance of the transferring power ranges from 5 mm to 25 mm.

11. The wireless power system of claim 1 , wherein the transmitting coil comprises a transmitting coil surface, and wherein a surface of the magnetic backing is equal to or greater than the transmitting coil surface.

12. The wireless power system of claim 1 , wherein the magnetic backing comprises a surface area between 700 mm 2 and 10,000 mm 2 .

13. The wireless power system of claim 1 , wherein the magnetic backing comprises at least one horizontal plane.

14. The wireless power system of claim 1 , wherein the one or more transmitting electronics further comprises a tuning circuit.

15. The wireless power system of claim 14 , wherein, when the tuning circuit is adjusted, a resonant frequency of an LC tank of the tuning circuit resonates at a frequency lower than an operating frequency of the wireless power system.

16. The wireless power system of claim 1 , wherein the magnetic core resides at an inner diameter of the transmitting coil, and wherein the transmitting coil and the magnetic core comprise a gap of at least 2 mm located therebetween.

17. The wireless power system of claim 1 , wherein the magnetic backing or magnetic core comprises a ferrite material that comprises a ferrite body, and wherein the ferrite body comprises a single, unitary constituent, the single unitary constituent further comprising one or more structural components.

18. The wireless power system of claim 1 , wherein either the transmitting coil, the receiving coil, or both comprise one of a single coil, a multi-layer coil, a multi-tiered coil, or combinations thereof.

19. The wireless power system of claim 1 , wherein one or more connection ends of the transmitting coil is electrically connected to the one or more transmitting electronics through an opening between two ends of the magnetic ring.

20. A wireless power system for transferring power, the wireless power system comprising:
a receiving coil;
one or more receiving electronics electrically connected to the receiving coil;
a transmitting coil assembly comprising:
a magnetic backing;
a magnetic core affixed to a given surface of the magnetic backing, wherein the magnetic backing extends beyond the magnetic core; and
a transmitting coil that surrounds the magnetic core, wherein the transmitting coil is configured to couple to the receiving coil; and

one or more transmitting electronics electrically connected to the transmitting coil, wherein at least one of the one or more transmitting electronics comprises:
a control system loop that is configured to vary one or more of a frequency, an input voltage, an input current, or a duty cycle; and
a tuning circuit comprising an LC tank, wherein when the tuning circuit is adjusted, a resonant frequency of the LC tank resonates at a frequency lower than an operating frequency of the wireless power system.

21. The wireless power system of claim 20 , wherein the magnetic backing or magnetic core comprises a ferrimagnetic material.

22. The wireless power system of claim 20 , wherein the magnetic backing or magnetic core comprises a magnetic shielding material.

23. The wireless power system of claim 20 , wherein an operating frequency of the wireless power system ranges from 25 kHz to 300 kHz.

24. The wireless power system of claim 20 , wherein the transferring power ranges from 1 nW to 30 W.

25. The wireless power system of claim 20 , wherein a coil-to-coil distance of the transferring power ranges from 5 mm to 25 mm.

26. The wireless power system of claim 20 , wherein the transmitting coil comprises a transmitting coil surface, and wherein a surface of the magnetic backing is equal to or greater than the transmitting coil surface.

27. The wireless power system of claim 20 , wherein the transmitting coil assembly further comprises a magnetic ring that surrounds at least a portion of the magnetic backing.

Assignees

• Nucurrent Inc

Inventors

• Shostak Pavel
• Los Oleg
• Wadkar Unnati
• Luzinski Jason
• Alam Nazmul
• Melone Mark D
• Zamborsky Matt
• Babcock Jacob
• Peralta Alberto
• Frysz Christine

Classifications

• H01F38/14 Primary

  Inductive couplings {(for wireless supply or distribution of electric power using inductive coupling H02J50/10)} · CPC title

• H02J50/005

  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 title

• H02J50/12 Primary

  of the resonant type · CPC title

• H01F27/366

  made of ferromagnetic material · CPC title

• H01F27/36

  Electric or magnetic shields or screens (movable for varying inductance H01F21/10) · CPC title