Coil module

Abstract

A coil module includes a first coil assembly and a second coil assembly. The first coil assembly includes a first coil and a first magnetic element. The second coil assembly includes a second coil. The first coil has a first winding shaft. The first magnetic element corresponds to the first coil. The second coil corresponds to the first coil and is electrically independent of the first coil. The first magnetic element is configured to increase a coupling coefficient between the first coil and the second coil.

Description

Technical Field

[0001] This disclosure relates to a coil module, and more particularly to a coil module for wireless charging. Prior Technology

[0002] Wireless charging is an AC induction technology that utilizes the principle of electromagnetic wave induction. It typically involves generating an electromagnetic field in a coil within the wireless charging device, which in turn induces an AC signal between the coil in the wireless charging device and the receiving coil in the electronic device, thus enabling charging. Currently, various electronic devices with wireless charging capabilities often have diverse appearances; therefore, designing coil modules with excellent charging performance has become an important research topic. Summary of the Invention

[0003] One embodiment of the present invention provides a coil module, including a first coil assembly and a second coil assembly. The first coil assembly includes a first coil and a first magnetic element. The second coil assembly includes a second coil. The first coil has a first winding shaft. The first magnetic element corresponds to the first coil. The second coil corresponds to the first coil and is electrically independent of the first coil. The first magnetic element is configured to increase a coupling coefficient between the first coil and the second coil.

[0004] According to some embodiments disclosed herein, a first coil is disposed on the first magnetic element, which includes a first body, a first lead, and a second lead. The first lead is electrically connected to the second lead via the first body. The first magnetic element has iron oxide and is configured to adjust the electromagnetic field distribution around the first coil. The first magnetic element includes a first surface, a second surface, a first trench, a second trench, a third trench, and a first opening. The first surface has a planar structure. The second surface faces the opposite direction to the first surface. The first trench is located on the first surface and has a recessed structure and a depth. The second trench is located on the first surface and has a recessed structure, wherein the first coil is not disposed in the second trench. The third trench is located on the second surface and has a recessed structure, wherein the first coil is not disposed in the third trench. The fourth trench is located on the first surface and has a recessed structure, configured to accommodate the second lead of the first coil. The first trench and the fourth trench have a discontinuous structure, and the fourth trench is connected to the first trench via the first opening. The first opening is configured to accommodate the first lead of the first coil and communicates with the first surface and the second surface. The first coil is at least partially disposed in the first trench, and the depth of the first coil embedded in the first trench is greater than or equal to half of a maximum dimension of the first body of the first coil in a direction parallel to the first winding axis. When viewed along a direction perpendicular to the first winding axis, the first trench and the first coil at least partially overlap, and the first surface and the first coil at least partially overlap. In a direction perpendicular to the first surface, the maximum dimension of one of the first trenches is less than or equal to half of the maximum dimension of one of the first magnetic elements. The ratio of the shortest distance between one of the first and second surfaces to the shortest distance between the first trench and the second surface is less than or equal to 0.5, and the shortest distance between the first trench and the second surface is greater than or equal to 0.5 mm. The second lead is at least partially disposed in the first trench and includes a lead-out section, a bent section, and a connecting section. The first body is electrically connected to the lead-out section via the bent section. The first body is electrically connected to the bent section via a connecting section, wherein when viewed along a direction perpendicular to the first surface, the connecting section at least partially overlaps with both the first and fourth grooves, and the connecting section at least partially overlaps with the first lead. When viewed along a direction perpendicular to the first surface, the second lead at least partially overlaps with both the first and fourth grooves.

[0005] According to some embodiments disclosed herein, a first body has a first line segment. When viewed in a first cross-section perpendicular to an extension direction of the first line segment, a maximum dimension of the first line segment differs from a maximum dimension of a first groove. When viewed in the first cross-section, the first line segment and the first groove form a first gap and a second gap, which are located on opposite sides of the first line segment. The first gap and the second gap have a tapering structure, tapering towards the bottom of the first groove. When viewed in the first cross-section, the radius of curvature of the arc-shaped first line segment differs from the radius of curvature of the arc-shaped first groove. When viewed in the first cross-section, in a direction parallel to the first surface, a maximum width of the first groove differs from a maximum width of the second groove. When viewed in the first cross-section, in a direction parallel to the first surface, a maximum width of the first groove is greater than a maximum width of the third groove.

[0006] According to some embodiments disclosed herein, the first body further comprises a second line segment and a third line segment. The second line segment is adjacent to the first line segment, and one of the second line segments extends parallel to the first line segment. The third line segment is adjacent to the first line segment, and one of the third line segments extends parallel to the first line segment. When viewed along a direction perpendicular to the first surface, the first line segment is located between the second and third line segments. In the direction perpendicular to the first surface, the maximum dimension of the first groove is greater than half the maximum dimension of the first line segment. The shortest distance between the first line segment and one of the second line segments is the same as the shortest distance between the first line segment and one of the third line segments. The shortest distance between the first line segment and the second line segment is greater than or equal to half the maximum dimension of the first line segment in the direction perpendicular to the first surface. When viewed in a first cross-section, the radius of curvature of the first groove is less than 1.5 times the radius of curvature of the first line segment.

[0007] According to some embodiments disclosed herein, the coil module further includes a bonding element comprising a resin body and a thermally conductive unit. The resin body is made of resin. The thermally conductive unit is at least partially embedded in the resin body. A first coil is connected to a first magnetic element via the bonding element, the bonding element being at least partially located in a first gap and at least partially located in a second gap. In a direction perpendicular to the first surface, the maximum distance between the surface of one of the bonding elements and one of the first surfaces is different from the maximum distance between the first coil and one of the first surfaces. When viewed along a direction parallel to one of the first surfaces, the surface of the bonding element at least partially overlaps with the first coil. The thermal conductivity of one of the thermally conductive units is higher than that of one of the resin bodies, the thermal conductivity of the thermally conductive unit is higher than that of one of the first magnetic elements, and the permeability of one of the thermally conductive units is lower than that of one of the first magnetic elements. When viewed in a first cross-section, the radius of curvature of the first line segment is smaller than the radius of curvature of the first groove. When viewed in a first cross-section, in a direction parallel to the first surface, the maximum width of the first groove is greater than the maximum width of the second groove.

[0008] According to some embodiments disclosed herein, the coupling coefficient between the first coil and the second coil is between 0.7 and 0.9. The first body includes a metal wire and an insulating layer covering the metal wire, the ratio of the diameter of the metal wire to the thickness of the insulating layer being between 10 and 500. The diameter of the metal wire is greater than 1 mm. In the direction perpendicular to the first surface, the maximum distance between the component surface and the first surface is less than the maximum distance between the first coil and the first surface.

[0009] According to some embodiments disclosed herein, the coil module further includes a first heat dissipation element configured to improve the heat dissipation efficiency of at least one of the first coil and the first magnetic element, wherein the material of the first heat dissipation element is different from that of the first magnetic element, and the thermal conductivity of the first heat dissipation element is higher than that of the first magnetic element. The first heat dissipation element includes a fifth groove, and when viewed along a direction parallel to the first winding axis, the first heat dissipation element and the first magnetic element at least partially overlap.

[0010] According to some embodiments disclosed herein, the coil module further includes a second heat dissipation element configured to allow gas flow around the first coil or the first magnetic element, and configured to allow gas flow in the second, third, and fifth trenches. The second, third, and fifth trenches extend to the edge of the first magnetic element and correspond to the second heat dissipation element. When viewed along a direction parallel to the first winding axis, the second heat dissipation element does not overlap with the first coil. The coil module further includes an outer casing having an inner surface facing the first coil. A gap exists between the first magnetic element and the outer casing. The second heat dissipation element is configured to allow gas flow in the gap between the first magnetic element and the outer casing. A gap also exists between the first coil and the outer casing, and the second heat dissipation element is configured to allow gas flow in the gap between the first coil and the outer casing.

[0011] According to some embodiments disclosed herein, the coil module further includes a control component, a storage component, and a sensing component. A second magnetic element corresponds to a second coil. The control component is electrically connected to the second coil. The storage component is configured to store electrical charge and is electrically connected to the first coil. The sensing component is electrically connected to the control component and configured to sense the temperature of any one of the storage component, the first coil, the second coil, or the first magnetic element; the sensing component outputs a temperature signal to the control component. When the amount of electrical charge stored in the storage component is between a first preset value and a second preset value, the control component outputs a first transmission signal to the second coil. The first preset value is less than the second preset value. When the amount of electrical charge stored in the storage component is between a fourth preset value and a third preset value, the control component outputs a second transmission signal to the second coil. The fourth preset value is less than the third preset value. The fourth preset value is greater than the second preset value. The power of the second transmission signal is greater than 15W. The power of one of the first transmission signals is greater than the power of one of the second transmission signals. The frequency of one of the first transmission signals is different from the frequency of one of the second transmission signals. The amplitude of one current in the first transmission signal differs from the amplitude of one current in the second transmission signal. The amplitude of one voltage in the first transmission signal also differs from the amplitude of one voltage in the second transmission signal. When the amount of electricity stored in the storage component is between a second preset value and a fourth preset value, the control component outputs a third transmission signal to the second coil. The power of the third transmission signal is less than the power of the first transmission signal. The power of the third transmission signal is greater than the power of the second transmission signal; the power of the third transmission signal can be any value between the power of the first and second transmission signals. When the sensed temperature is less than or equal to a first preset temperature, the third heat dissipation element operates in a first mode. When the sensed temperature is greater than a second preset temperature, the third heat dissipation element operates in a second mode. The first preset temperature is less than the second preset temperature. The heat dissipation efficiency of the first mode is less than that of the second mode. When the sensed temperature is greater than a third preset temperature, the control component changes from outputting the first transmission signal to outputting either the second or third transmission signal to the second coil. The second preset temperature is less than the third preset temperature. When the sensed temperature exceeds a fourth preset temperature, the control component stops outputting a signal to the second coil. The third preset temperature is less than the fourth preset temperature.

[0012] According to some embodiments disclosed herein, the second coil assembly further includes a second magnetic element and a third heat dissipation element. The second magnetic element corresponds to the second coil. The third heat dissipation element is configured to generate airflow around at least one of the second coil and the second magnetic element. The coil module further includes a rotating assembly via which the first coil assembly is movable relative to the second coil assembly. The rotating assembly includes a protruding element and a receiving element. The protruding element extends along a direction parallel to the first winding axis. The receiving element receives at least a portion of the protruding element and has either a recessed or open structure. The protruding element is received within the receiving element, which is integrally formed with either the first magnetic element or the second magnetic element. Simple Explanation of the Diagram

[0013] This disclosure will become clear through the following detailed description and accompanying illustrations. It should be emphasized that, in accordance with industry standard practice, the features are not drawn to scale and are for illustrative purposes only. In fact, the dimensions of the features may be arbitrarily enlarged or reduced for clarity. Figure 1 is a block diagram of the components of a coil module according to one embodiment of the present disclosure. Figure 2 is a perspective view of a first coil assembly and a second coil assembly according to one embodiment of the present disclosure. Figure 3 is an exploded view of a first coil assembly according to an embodiment of the present disclosure. Figure 4 is a top view of some elements of a first coil assembly according to an embodiment of the present disclosure. Figure 5 is a bottom view of a first magnetic element according to an embodiment of the present disclosure. Figure 6 is an enlarged cross-sectional view of a portion of the components along the A-A' tangent in Figure 1. Figure 7 is an exploded view of some components of a second coil assembly according to an embodiment of the present disclosure. Implementation

[0014] To make the objectives, features, and advantages of this disclosure more apparent and understandable, specific embodiments are provided below, along with detailed descriptions in conjunction with the accompanying drawings. The arrangement of elements in the embodiments is for illustrative purposes only and is not intended to limit the scope of this disclosure. Furthermore, the repetition of some reference numerals in the embodiments is for simplification and does not imply any correlation between different embodiments. Directional terms used in the following embodiments, such as up, down, left, right, front, or back, are merely for reference to the accompanying drawings. Therefore, the directional terms used are for illustrative purposes and not for limiting the scope of this disclosure.

[0015] Furthermore, relative terms such as "lower" or "bottom" and "higher" or "top" may be used in the embodiments to describe the relative relationship of one element to another. It is understood that if the illustrated device is flipped upside down, the element described as being on the "lower" side will become the element on the "higher" side.

[0016] Here, the terms "about" or "approximately" generally mean within 20% of a given value or range, preferably within 10%, and even more preferably within 5%. The quantities given here are approximate, meaning that the meaning of "about" or "approximately" may be implied even without specific explanation.

[0017] Please refer to Figures 1 and 2. Figure 1 is a block diagram of the components of a coil module 1 according to an embodiment of the present disclosure. Figure 2 is a perspective view of a first coil assembly 100 and a second coil assembly 200 according to an embodiment of the present disclosure. As shown in Figure 1, the coil module 1 can be used for wireless data or energy transmission and includes a first coil assembly 100, a second coil assembly 200, a rotation assembly 300, a control assembly 400, a storage assembly 500, and a sensing assembly 600. The first coil assembly 100 corresponds to the second coil assembly 200, and the first coil assembly 100 and the second coil assembly 200 can be connected via the rotation assembly 300. The control assembly 400 is electrically connected to the second coil assembly 200. The storage assembly 500 is configured to store an electrical charge and is electrically connected to the first coil assembly 100. The sensing assembly 600 is electrically connected to the control assembly 400.

[0018] More specifically, the first coil assembly 100 is movable relative to the second coil assembly 200 via a rotating assembly 300, as shown in Figure 2. The rotating assembly 300 includes a protruding element 310 and a receiving element 320. The protruding element 310 extends along a direction parallel to a first winding axis A1 and can be a separate element or integrally formed with either the first coil assembly 100 or the second coil assembly 200. The receiving element 320 accommodates at least a portion of the protruding element 310 and can have either a recessed structure or an open structure. The receiving element 320 can be integrally formed with either the first coil assembly 100 or the second coil assembly 200, and the protruding element 310 is accommodated within the receiving element 320.

[0019] In this embodiment, both the first coil assembly 100 and the second coil assembly 200 have an open receiving element 320, and the protruding element 310 is an independent element disposed between the first coil assembly 100 and the second coil assembly 200 and passes through the receiving elements 320 of the first coil assembly 100 and the second coil assembly 200 respectively, so that the first coil assembly 100 and the second coil assembly 200 can rotate relative to each other.

[0020] With this configuration, the first coil assembly 100 and the second coil assembly 200 can still transmit energy or information to each other even when they are not fully aligned with the first winding shaft A1. In some embodiments, the second coil assembly 200 is used to transmit energy, the first coil assembly 100 is used to receive energy, and the first coil assembly 100 is used to receive the energy transmitted by the second coil assembly 200.

[0021] Please refer to Figures 3 through 6. Figure 3 is an exploded view of a first coil assembly 100 according to an embodiment of the present disclosure. Figure 4 is a top view of some components of the first coil assembly 100 according to an embodiment of the present disclosure. Figure 5 is a bottom view of a first magnetic element 120 according to an embodiment of the present disclosure. Figure 6 is an enlarged cross-sectional view of some components along the tangent line A-A' in Figure 1. The first coil assembly 100 includes a first coil 110, a first magnetic element 120, a bonding element 130, a first heat dissipation element 140, a second heat dissipation element 150, and an outer casing 160.

[0022] As shown in Figure 4, the first coil 110 has a first winding shaft A1 and is disposed on the first magnetic element 120. The first coil 110 includes a first body 111, a first lead 112, and a second lead 113. The first lead 112 is electrically connected to the second lead 113 via the first body 111. The second lead 113 includes a lead-out section 113A, a bent section 113B, and a connecting section 113C. The first body 111 is electrically connected to the lead-out section 113A in sequence via the connecting section 113C and the bent section 113B.

[0023] The first body 111 includes a metal wire and an insulating layer covering the metal wire. The ratio of the diameter of the metal wire to the thickness of the insulating layer is between 10 and 500. In this embodiment, the diameter of the metal wire is greater than 1 mm. The first body 111 is wound from the inner side near the first winding shaft A1 to the outer side. Based on the distance from the first winding shaft A1, the first body 111 can be divided into multiple segments. In this embodiment, the relationship between the segments is illustrated by a first segment 111A, a second segment 111B, and a third segment 111C. The second segment 111B and the third segment 111C are adjacent to the first segment 111A, and the extension directions of the second segment 111B and the third segment 111C are parallel to the first segment 111A. As shown in Figures 4 and 6, when viewed along the first winding axis A1, the first line segment 111A is located between the second line segment 111B and the third line segment 111C. The shortest distance L12 min between the first line segment 111A and the second line segment 111B is the same as the shortest distance L13 min between the first line segment 111A and the third line segment 111C. The shortest distance L12 min between the first line segment 111A and the second line segment 111B is greater than or equal to half of a maximum dimension D max of the first line segment 111A in the direction parallel to the first winding axis A1.

[0024] In this embodiment, the first coil 110 can serve as a charging coil for wireless charging by a charging component (such as the second coil component 200). For example, the first coil 110 can be a resonant charging coil based on the Alliance for Wireless Power (A4WP) standard, but is not limited thereto. Alternatively, the first coil 110 can be based on the Wireless Power Consortium (WPC) standard, such as the Qi standard, to serve as an inductive charging coil. Therefore, this implementation allows the first coil 110 to simultaneously support different charging methods, thereby increasing its applicability. For example, inductive operation can be used at close range (e.g., less than 1 cm), while resonant operation can be used at long range.

[0025] The first magnetic element 120 corresponds to the first coil 110 and is configured to adjust the electromagnetic field distribution around the first coil 110, and to increase the coupling coefficient between the first coil 110 and a second coil 210 of the second coil assembly 200. The first magnetic element 120 may contain iron oxide, but is not limited to this. For example, in other embodiments, the first magnetic element 120 may also include a nanocrystalline material. The first magnetic element 120 may have a permeability corresponding to the first coil 110, thereby concentrating the electromagnetic waves of the first coil 110.

[0026] As shown in Figures 4 to 6, the first magnetic element 120 includes a first surface F1, a second surface F2, a first groove 121, a second groove 122, a third groove 123, a fourth groove 124, and a first opening 125. The first surface F1 has a planar structure, the second surface F2 faces the opposite direction to the first surface F1, and the first surface F1 and the second surface F2 are perpendicular to the first winding shaft A1.

[0027] The first groove 121 is located on the first surface F1 and has a recessed structure with a depth D1, such that the first coil 110 is at least partially disposed in the first groove 121. In this embodiment, when viewed along the first winding axis A1, the first groove 121 is arranged in five sections from the inside to the outside along a direction perpendicular to the first winding axis A1, such that the first coil 110 can be wound five turns along the shape of the first groove 121. The depth D1 of the first coil 110 embedded in the first groove 121 is greater than or equal to half of the maximum dimension Dmax of the first coil 110 in the direction parallel to the first winding axis A1.

[0028] The second groove 122 is also located on the first surface F1 and has a recessed structure. When viewed along the first winding axis A1, the second groove 122 has two sections near the first winding axis A1 and two sections away from the first winding axis A1 along a direction perpendicular to the first winding axis A1. The first coil 110 is disposed in the first groove 121 but not in the second groove 122.

[0029] As shown in Figure 5, the third trench 123 is located on the second surface F2 and has a recessed structure. The first coil 110 is not disposed in the third trench 123. In this embodiment, the second trench 122 and the third trench 123 are symmetrically arranged on the first surface F1 and the second surface F2 to increase heat dissipation efficiency. As shown in Figure 6, relative to the first trench 121, the second trench 122 and the third trench 123 each have a depth D2, and the depth D2 is less than the depth D1. Furthermore, in a direction parallel to the first surface F1, the maximum width W1 max of one of the first trenches 121 is different from the maximum width W2 max of one of the second trenches 122 and the maximum width W3 max of one of the third trenches. In this embodiment, the maximum width W1 max of the first trench 121 is greater than the maximum width W2 max of the second trench 122 and the maximum width W3 max of the third trench 123.

[0030] It should be noted that, although in the embodiment shown in Figure 6, five first grooves 121 are surrounded by four second grooves 122 with circular shapes, and third grooves 123 of the same shape are provided on the second surface F2, the shape, number, and configuration of the first grooves 121, second grooves 122, and third grooves 123 are not limited thereto and can be changed as needed. For example, in some embodiments, the number of first grooves 121 can be increased to increase the number of turns of the first coil 110, or more than four second grooves 122 can be provided around the first grooves 121, and more third grooves 123 than the number of second grooves 122 can be provided on the second surface F2, and the third grooves 123 and the second grooves 122 can be asymmetrically configured, etc.

[0031] As shown in Figure 4, the fourth groove 124 is located on the first surface F1 and has a recessed structure. Similar to the first groove 121, the fourth groove 124 also accommodates a portion of the first coil 110. More specifically, since the fourth groove 124 connects to the first groove 121 via the first opening 125, that is, the first opening 125 is located between the first groove 121 and the fourth groove 124, and the first groove 121 and the fourth groove 124 have a discontinuous structure, the connecting segment 113C of the second lead 113 of the first coil 110 is located in both the first groove 121 and the fourth groove 124 and spans the first opening 125. When viewed along a direction perpendicular to the first surface F1 (that is, along the first winding axis A1), the connecting segment 113C of the second lead 113 at least partially overlaps with both the first groove 121 and the fourth groove 124.

[0032] The first opening 125 is configured to accommodate the first lead 112 of the first coil 110, and the first opening 125 connects the first surface F1 and the second surface F2. When viewed along a direction perpendicular to the first surface F1, the connecting segment 113C at least partially overlaps with the first lead 112.

[0033] When viewed along a first cross-section S perpendicular to the extension direction of the first line segment 111A, i.e., along the cross-section of line segment A-A' in Figure 2, as shown in Figure 6, the maximum dimension Dmax of the first line segment 111A differs from the maximum dimension tmax of the first groove 121. More specifically, in the direction perpendicular to the first surface F1, the maximum dimension tmax of the first groove 121 is greater than half of the maximum dimension Dmax of the first line segment 111A. Therefore, when viewed along a direction perpendicular to the first winding axis A1, the first groove 121 at least partially overlaps with the first coil 110, and the first surface F1 at least partially overlaps with the first coil 110.

[0034] Furthermore, when viewed from the first cross section S, the first line segment 111A and the first groove 121 form a first gap G1 and a second gap G2. The first gap G1 and the second gap G2 are located on both sides of the first line segment 111A. The first gap G1 and the second gap G2 have a tapered structure. More specifically, since the first line segment 111A and the first groove 121 have different radii of curvature R1 and R2, respectively, the radius of curvature R1 of the first line segment 111A is smaller than the radius of curvature R2 of the first groove 121. In this embodiment, the radius of curvature R2 of the first groove 121 is less than 1.5 times the radius of curvature R1 of the first line segment 111A. Therefore, the first gap G1 and the second gap G2 tapere toward the bottom of the first groove 121.

[0035] To avoid the first groove 121 becoming too deep (D1) and causing a hole, the maximum dimension tmax of the first groove 121 in the direction perpendicular to the first surface F1 is less than or equal to half of the maximum dimension Tmax of the first magnetic element 120. That is, the ratio of the shortest distance F12min between the first surface F1 and the second surface F2 to the shortest distance Wmin between the first groove 121 and the second surface F2 is less than or equal to 0.5. However, in this embodiment, the shortest distance Wmin between the first groove 121 and the second surface F2 is greater than or equal to 0.5 mm.

[0036] By utilizing the special structure of the first magnetic element 120, the first coil 110 can be embedded therein, thereby achieving better electromagnetic shielding, reducing proximity effect, and increasing the coupling coefficient between the first coil 110 and the second coil 210, so that the coupling coefficient between the first coil 110 and the second coil 210 is between 0.7 and 0.9. Therefore, when applied to wireless charging, the maximum charging distance can be increased, and high-power (above 15W) charging can be achieved.

[0037] Next, the bonding element 130 includes a resin body and a thermally conductive unit (not shown). The thermal conductivity of the thermally conductive unit is higher than that of the resin body and the first magnetic element 120, and the magnetic permeability of the thermally conductive unit is lower than that of the first magnetic element 120. In some embodiments, the resin body is made of resin material, and the thermally conductive unit is, for example, silver powder, at least partially embedded in the resin body. The resin body and the thermally conductive unit form a conductive silver paste, but this is not limited to this, and other suitable materials can also be used for the bonding element 130.

[0038] As shown in Figure 6, the first coil 110 is connected to the first magnetic element 120 via a connecting element 130, which is at least partially located in the first gap G1 and at least partially in the second gap G2. In the direction perpendicular to the first surface F1, the maximum distance D13 between one of the connecting element surfaces F3 and one of the first surfaces F1 differs from the maximum distance D1C between the first coil 110 and one of the first surfaces F1; more specifically, the maximum distance D13 between the connecting element surface F3 and the first surface F1 is smaller than the maximum distance D1C between the first coil 110 and the first surface F1. When viewed along a direction parallel to one of the first surfaces F1, the connecting element surface F3 at least partially overlaps with the first coil 110.

[0039] The first heat dissipation element 140 is configured to improve the heat dissipation efficiency of at least one of the first coil 110 and the first magnetic element 120. The material of the first heat dissipation element 140 is different from that of the first magnetic element 120, and the thermal conductivity of the first heat dissipation element 140 is higher than that of the first magnetic element 120. The first heat dissipation element 140 has a hollow flat plate shape and is connected to a second surface F2 of the first magnetic element 120. On a surface opposite to the second surface F2, it includes a plurality of fins F and a plurality of fifth grooves 141. In this embodiment, as shown in Figure 6, the fifth grooves 141 are formed by two adjacent fins F. When viewed along a direction parallel to the first winding axis A1, the first heat dissipation element 140 and the first magnetic element 120 at least partially overlap.

[0040] The second heat dissipation element 150 can be a fan, positioned above the first surface F1 and below the first heat dissipation element 140, to allow airflow around the first coil 110 or the first magnetic element 120, and to allow airflow in the second groove 122, the third groove 123, and the fifth groove 141. In this embodiment, the second groove 122, the third groove 123, and the fifth groove 141 extend to the edge of the first magnetic element 120 and correspond to the second heat dissipation element 150. When viewed along a direction parallel to the first winding axis, the second heat dissipation element 150 does not overlap with the first coil 110.

[0041] The outer cover 160 consists of a top cover 161 and a base 162, for housing the first coil 110, the first magnetic element 120, the bonding element 130, the first heat dissipation element 140, and the second heat dissipation element. The outer cover 160 has an inner surface facing the first coil 110. A gap exists between the first magnetic element 120 and the outer cover 160. The second heat dissipation element 150 is configured to allow gas to flow in the gap between the first magnetic element 120 and the outer cover 160.

[0042] Although the outer cover 160 in the above embodiment has a shape similar to that of the first magnetic element 120, it is not limited thereto, and the outer cover can have any shape. Furthermore, the first coil 110 and the first magnetic element 120 are not limited to circles, and can have any shape that fits between them.

[0043] Next, referring to Figures 1, 2, and 7, the operation of coil module 1 will be explained. Figure 7 is an exploded view of some components of the second coil assembly 200. The second coil assembly 200 has a structure similar to that of the first coil assembly 100, including a second coil 210, a second magnetic element 220, and a third heat dissipation element 230. The second coil 210 is electrically independent from the first coil 110 and can be a transmitting coil to generate inductive coupling with the first coil 110 (receiving coil). In this way, the second coil assembly 200 can wirelessly supply power to the first coil assembly 100, and the first coil assembly 100 can store the obtained power in the storage component 500 (e.g., a rechargeable battery).

[0044] The second magnetic element 220 corresponds to the second coil 210, and the third heat dissipation element 230 is similar to the second heat dissipation element 150 and can be a fan, configured to cause airflow around at least one of the second coil 210 and the second magnetic element 220.

[0045] The control component 400 is electrically connected to the second coil 210, the storage component 500 is electrically connected to the first coil 110, and the sensing component 600 is configured to sense the temperature of any one of the storage component 500, the first coil 110, the second coil 210, or the first magnetic element 120, and output the temperature information to the control component 400.

[0046] In this embodiment, the amount of electricity stored in the storage component 500 can be controlled by distinguishing four preset values: a first preset value, a second preset value, a third preset value, and a fourth preset value. The first preset value is less than the second preset value, the fourth preset value is less than the third preset value, and the second preset value is less than the fourth preset value. For example, the first preset value is 0%, the second preset value is 30%, the third preset value is 100%, and the fourth preset value is 70%. However, the preset values ​​are not limited to the above range and can be changed as needed. When the amount of electricity stored in the storage component 500 is between the first preset value and the second preset value (e.g., 0-30%), the control component 400 outputs a first transmission signal to the second coil 210.

[0047] When the amount of electricity stored in the storage component 500 is between a fourth preset value and a third preset value (e.g., 70-100%), the control component 400 outputs a second transmission signal to the second coil 210. Specifically, the power of one of the first transmission signals is greater than the power of one of the second transmission signals, and the power of the second transmission signal is greater than 15W. The frequencies of the first and second transmission signals are different, the amplitudes of the currents and voltages of the first and second transmission signals are different.

[0048] When the amount of electricity stored in the storage component 500 is between a second preset value and a fourth preset value (e.g., 30-70%), the control component 400 outputs a third transmission signal to the second coil 210. The power of the third transmission signal is less than the power of the first transmission signal, and the power of the third transmission signal is greater than the power of the second transmission signal.

[0049] In other words, when the first coil assembly 100, acting as the receiving end, is not fully charged, the control assembly 400 controls the second coil assembly 200 to transfer energy (i.e., charge) to the first coil assembly 100. Compared to the conventional charging power range of 5W-15W, this embodiment achieves high-power (greater than 15W) charging. Furthermore, the charging power when the battery level is low is greater than the charging power when the battery level is high.

[0050] Furthermore, the power of the third transmission signal can be any value between the power of the first transmission signal and the power of the second transmission signal. That is, the power can be continuously adjusted rather than switched in segments. For example, a common adjustment method is a two-stage switching between 5W and 10W; in this embodiment, it can be adjusted to 5.1W, 5.2W…10W, etc. Alternatively, the power can also be adjusted by frequency, voltage, or current.

[0051] In this embodiment, the temperature sensed by the sensing component 600 can be distinguished by three preset temperatures to control the output signal and the operating mode of the third heat dissipation element 230. The four preset temperatures are a first preset temperature, a second preset temperature, a third preset temperature, and a fourth preset temperature. The first preset temperature is lower than the second preset temperature, the second preset temperature is lower than the third preset temperature, and the third preset temperature is lower than the fourth preset temperature.

[0052] When the sensed temperature is less than or equal to a first preset temperature, the third heat dissipation element 230 operates in a first mode. When the sensed temperature is greater than a second preset temperature, the third heat dissipation element 230 operates in a second mode. The heat dissipation efficiency of the first mode is less than that of the second mode. When the sensed temperature is greater than a third preset temperature, the control component 400 changes from outputting a first transmission signal to outputting a second or third transmission signal to the second coil 210. When the sensed temperature is greater than a fourth preset temperature, the control component 400 stops outputting signals to the second coil 210.

[0053] In other words, if the sensing component 600 detects that the temperature has risen above the second preset temperature, it controls the third heat dissipation element 230 to improve its heat dissipation efficiency, for example, by increasing the rotation speed of the third heat dissipation element 230. If the temperature rises above the third preset temperature, and the rotation speed of the third heat dissipation element 230 can no longer be increased, and the coil module 1 is charging at high power, a signal can be output to make the coil module 1 charge at a lower power. However, if the temperature still exceeds the fourth preset temperature, charging will stop.

[0054] As described above, this disclosed embodiment provides a coil module including a first coil, a first magnetic element, and a second coil. The first magnetic element corresponds to the first coil. The second coil corresponds to the first coil and is electrically independent of the first coil. The first magnetic element is configured to increase the coupling coefficient between the first coil and the second coil. Due to the special structure of the first magnetic element, the first coil can be embedded therein, thereby achieving better electromagnetic shielding, reducing proximity effects, and increasing the coupling coefficient between the first coil and the second coil, such that the coupling coefficient between the first coil and the second coil is between 0.7 and 0.9. Therefore, when applied to wireless charging, the maximum charging distance can be increased, and high-power (above 15W) charging can be achieved.

[0055] While the embodiments and advantages of the present invention have been disclosed above, it should be understood that anyone skilled in the art can make modifications, substitutions, and refinements without departing from the spirit and scope of the invention. Furthermore, the scope of protection of the present invention is not limited to the processes, machines, manufacturing, material composition, apparatus, methods, and steps described in the specific embodiments of the specification. Anyone skilled in the art can understand from the disclosure of the present invention that current or future developed processes, machines, manufacturing, material composition, apparatus, methods, and steps can be used according to the present invention as long as they can perform substantially the same function or obtain substantially the same results in the embodiments described herein. Therefore, the scope of protection of the present invention includes the aforementioned processes, machines, manufacturing, material composition, apparatus, methods, and steps. In addition, each claim constitutes an individual embodiment, and the scope of protection of the present invention also includes combinations of various claim claims and embodiments.

[0056] 1: Coil Module 100: First coil assembly 110: First coil 111:First body 111A: First line segment 111B: Second line segment 111C: Third line segment 112: First Lead 113: Second lead 120: First magnetic element 121: First trench 122: Second trench 123: Third trench 124: Fourth trench 125: First Opening 130: Next component 140: First heat dissipation element 141: Fifth trench 150: Second heat dissipation element 160: Outer Cover 200: Second coil assembly 210: Second coil 220: Second magnetic element 230: Third heat dissipation element 300: Rotating assembly 310: Protruding Components 320: Housing element 400: Control Components 500: Storage Components 600: Sensing Components A1: First winding shaft D1, D2: Depth D13, D1C: Maximum distance D_max, T_max, t_max: Maximum dimensions F: Fin F1: First surface F2: Second surface F3: Next to the component surface F12 min, L12 min, L12 min, W min: Shortest distance G1: First gap G2: Second gap R1, R2: Radius of curvature S: First section W1 max, W2 max, W3 max: Maximum width

Claims

1. A coil module, comprising: A first coil assembly includes: a first coil having a first winding shaft; a first magnetic element corresponding to the first coil; and a second coil assembly includes: a second coil corresponding to the first coil and electrically independent of the first coil; and a rotating assembly via which the first coil assembly is movable relative to the second coil assembly, wherein the first magnetic element is configured to increase a coupling coefficient between the first coil and the second coil.

2. The coil module as claimed in claim 1, wherein the first coil is disposed on the first magnetic element, including a first body, a first lead, and a second lead, the first lead being electrically connected to the second lead via the first body; wherein the first magnetic element has iron oxide and is configured to adjust the electromagnetic field distribution around the first coil, including: A first surface having a planar structure; and a second surface facing in the opposite direction to the first surface. A first trench located on the first surface and having a recessed structure and a depth; a second trench located on the first surface and having a recessed structure, wherein the first coil is not disposed in the second trench; a third trench located on the second surface and having a recessed structure, wherein the first coil is not disposed in the third trench; a fourth trench located on the first surface and having a recessed structure, configured to receive the second lead of the first coil, the first trench and the fourth trench having a discontinuous structure; and a first opening configured to receive the first lead of the first coil, and the first opening communicating with the first surface and the second surface, the fourth trench being connected to the first trench via the first opening; wherein the first coil is at least partially disposed in the first trench, and the depth to which the first coil is embedded in the first trench is greater than or equal to half a maximum dimension of the first body of the first coil in a direction parallel to the first winding axis; When viewed along a direction perpendicular to the first winding axis, the first groove at least partially overlaps with the first coil, and the first surface at least partially overlaps with the first coil; wherein, in a direction perpendicular to the first surface, the maximum dimension of one of the first grooves is less than or equal to half of the maximum dimension of the first magnetic element; wherein the ratio of the shortest distance between the first surface and one of the second surfaces to the shortest distance between the first groove and one of the second surfaces is less than or equal to 0.5, and the shortest distance between the first groove and the second surface is greater than or equal to 0.5 mm; wherein the second lead is at least partially disposed in the first groove, comprising: a lead-out section; a bent section, through which the first body is electrically connected to the lead-out section; and a connecting section, through which the first body is electrically connected to the bent section, wherein, when viewed along the direction perpendicular to the first surface, the connecting section of the second lead at least partially overlaps with both the first groove and the fourth groove, and the connecting section at least partially overlaps with the first lead.

3. The coil module as claimed in claim 2, wherein the first body has a first line segment, and when viewed in a first cross-section perpendicular to an extension direction of the first line segment, a maximum dimension of the first line segment is different from the maximum dimension of the first groove; wherein when viewed in the first cross-section, the first line segment and the first groove form a first gap and a second gap, the first gap and the second gap being located on opposite sides of the first line segment, the first gap and the second gap having a tapering structure, the first gap and the second gap tapering toward the bottom of the first groove; wherein when viewed in the first cross-section, the radius of curvature of the first line segment having an arcuate structure is different from the radius of curvature of the first groove having an arcuate structure; wherein when viewed in the first cross-section, in the direction parallel to the first surface, a maximum width of the first groove is different from a maximum width of the second groove; wherein when viewed in the first cross-section, in the direction parallel to the first surface, a maximum width of the first groove is greater than a maximum width of the third groove.

4. The coil module as claimed in claim 3, wherein the first body further comprises: a second segment adjacent to the first segment, one of the second segment extending in a direction parallel to the first segment; and a third segment adjacent to the first segment, one of the third segment extending in a direction parallel to the first segment; wherein, when viewed along the direction perpendicular to the first surface, the first segment is located between the second segment and the third segment; wherein, in the direction perpendicular to the first surface, the maximum dimension of the first groove is greater than half of the maximum dimension of the first segment; wherein the shortest distance between the first segment and one of the second segments and the shortest distance between the first segment and one of the third segments are the same; wherein the shortest distance between the first segment and the second segment is greater than or equal to half of a maximum dimension of the first segment in the direction perpendicular to the first surface; wherein, when viewed in the first cross-section, the radius of curvature of the first groove is less than 1.5 times the radius of curvature of the first segment.

5. The coil module as described in claim 4 further includes a connecting element, comprising: A resin body, made of resin material; And a heat-conducting unit, at least partially embedded in the resin body; The first coil is connected to the first magnetic element via the bonding element, the bonding element being at least partially located in the first gap and at least partially located in the second gap; wherein, in the direction perpendicular to the first surface, the maximum distance between the bonding element surface and the first surface is different from the maximum distance between the first coil and the first surface; wherein, when viewed along the direction parallel to the first surface, the bonding element surface at least partially overlaps with the first coil; wherein, the thermal conductivity of one of the thermally conductive units is higher than that of the resin body, the thermal conductivity of the thermally conductive unit is higher than that of the first magnetic element, and the permeability of one of the thermally conductive units is lower than that of the first magnetic element; wherein, when viewed in the first cross-section, the radius of curvature of the first line segment is smaller than the radius of curvature of the first groove; wherein, when viewed in the first cross-section, in the direction parallel to the first surface, the maximum width of the first groove is greater than the maximum width of the second groove.

6. The coil module as claimed in claim 5, wherein the coupling coefficient between the first coil and the second coil is between 0.7 and 0.9; wherein the first body includes a metal wire and an insulating layer covering the metal wire, the ratio of the diameter of the metal wire to the thickness of the insulating layer being between 10 and 500; wherein the diameter of the metal wire is greater than 1 mm; wherein in the direction perpendicular to the first surface, the maximum distance between the surface of the connecting element and the first surface is less than the maximum distance between the first coil and the first surface.

7. The coil module as claimed in claim 3 further includes a first heat dissipation element configured to improve the heat dissipation efficiency of at least one of the first coil and the first magnetic element, wherein the material of the first heat dissipation element is different from that of the first magnetic element, and the thermal conductivity of the first heat dissipation element is higher than that of the first magnetic element, the first heat dissipation element includes a fifth groove, and when viewed along a direction parallel to the first winding axis, the first heat dissipation element and the first magnetic element at least partially overlap.

8. The coil module as claimed in claim 7 further includes a second heat dissipation element configured to allow gas flow around the first coil or the first magnetic element, and configured to allow gas flow in the second trench, the third trench, and the fifth trench; wherein the second trench, the third trench, and the fifth trench extend to the edge of the first magnetic element and correspond to the second heat dissipation element; wherein when viewed along the direction parallel to the first winding axis, the second heat dissipation element does not overlap with the first coil; wherein the coil module further includes an outer casing having an inner surface facing the first coil, a gap between the first magnetic element and the outer casing, the second heat dissipation element configured to allow gas flow in the gap between the first magnetic element and the outer casing, and a gap between the first coil and the outer casing, the second heat dissipation element configured to allow gas flow in the gap between the first coil and the outer casing.

9. The coil module as described in claim 2, further comprising: A control component is electrically connected to the second coil; A storage component configured to store an electrical charge and electrically connected to the first coil; The system includes a sensing component electrically connected to the control component and configured to sense the temperature of any one of the storage component, the first coil, the second coil, or the first magnetic element. The sensing component outputs a temperature signal to the control component. When the amount of electricity stored in the storage component is between a first preset value and a second preset value, the control component outputs a first transmission signal to the second coil. The first preset value is less than the second preset value. When the amount of electricity stored in the storage component is between a fourth preset value and a third preset value, the control component outputs a second transmission signal to the second coil. The fourth preset value is less than the third preset value. The fourth preset value is greater than the second preset value. The power of the second transmission signal is greater than 15W. The power of one of the first transmission signals is greater than the power of one of the second transmission signals. The frequency of one of the first transmission signals is different from the frequency of one of the second transmission signals. The amplitude of one of the currents in one of the first transmission signals is different from the amplitude of one of the currents in one of the second transmission signals. The amplitude of one voltage of the first transmission signal is different from the amplitude of one voltage of the second transmission signal; when the amount of electricity stored in the storage component is between the second preset value and the fourth preset value, the control component outputs a third transmission signal to the second coil; the power of the third transmission signal is less than the power of the first transmission signal; the power of the third transmission signal is greater than the power of the second transmission signal; the power of the third transmission signal can be any value between the power of the first transmission signal and the power of the second transmission signal.

10. The coil module as claimed in claim 9, wherein the second coil assembly further comprises: A second magnetic element, corresponding to the second coil; The system includes a third heat dissipation element configured to allow airflow around at least one of the second coil and the second magnetic element; wherein the third heat dissipation element operates in a first mode when the sensed temperature is less than or equal to a first preset temperature; wherein the third heat dissipation element operates in a second mode when the sensed temperature is greater than a second preset temperature; wherein the first preset temperature is less than the second preset temperature; wherein the heat dissipation efficiency of the first mode is less than the heat dissipation efficiency of the second mode; wherein when the sensed temperature is greater than a third preset temperature, the control component changes from outputting the first transmission signal to outputting the second transmission signal or the third transmission signal to the second coil; wherein the second preset temperature is less than the third preset temperature; wherein when the sensed temperature is greater than a fourth preset temperature, the control component stops outputting signals to the second coil; wherein the third preset temperature is less than the fourth preset temperature; wherein the rotating component includes: a protruding element extending along a direction parallel to the first winding axis; A receiving element that receives at least a portion of the protruding element, having any of the recessed or open structures, wherein the protruding element is received in the receiving element, and the receiving element is integrally formed with either the first magnetic element or the second magnetic element.

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