A medium to high power wireless charging coil structure

Abstract

The present invention relates to the technical field of charging coils, and specifically discloses a medium-to-high power wireless charging coil structure, including a coil structure, an isolation plate, a magnetic plate, a resonant capacitor group, and a heat dissipation structure that are stacked in sequence. The present invention realizes installation by stacking, and has a good thermal conductivity effect; by pouring glue, the cooperation of the sealing groove and the protrusion, it has a good sealing effect; by adjusting the connection relationship between the capacitors, the capacitance can be effectively changed; it has good thermal conductivity and heat dissipation performance, and can effectively reduce the heat generated by the internal resistance of the coil, eddy currents, and eddy currents induced by the leakage magnetic field of the heat dissipation structure. The reduction of heat will suppress the change of coil parameters and ensure the stability of the charging system.

Description

Technical Field

[0001] The present invention relates to the technical field of wireless charging, and in particular to a medium-to-high power wireless charging coil structure. Background Art

[0002] With the development of science and technology, warehousing logistics and inspection are gradually entering the era of unmanned electrical intelligence. Therefore, handling robots and inspection robots are now a major development trend. Electric energy, as the power source of robots, is a problem that must be solved at present, and one of the problems is unmanned charging. At present, there are contact charging lines, which use carbon brushes or contacts to transmit power, but they face the problems of surface oxidation, contact sparks, and the use environment must be in a dry environment, which makes their service life short and unsafe. The best way to solve these problems is to use a wireless charging system.

[0003] At present, although there are consumer-grade wireless charging devices on the market, their power is very small, generally only 10-20w maximum power output, which is far from enough to power robots. Summary of the invention

[0004] The technical problem to be solved by the present invention is to provide a medium to high power wireless charging coil structure.

[0005] The solution adopted by the present invention to solve the technical problem is:

[0006] A medium-to-high power wireless charging coil structure comprises a coil structure, an isolation plate, a magnetic plate, a resonant capacitor group, and a heat dissipation structure which are stacked in sequence.

[0007] In some possible implementations, in order to effectively achieve heat dissipation, the heat dissipation structure includes an air duct cover and a radiator which are arranged in sequence; the radiator is arranged between the resonant capacitor group and the air duct cover.

[0008] In some possible implementations, there is a gap between the radiator and the air duct cover, and the gap is 3-5 mm. The purpose of this arrangement is to allow air to flow in from the side.

[0009] In some possible embodiments, the radiator includes a substrate and a turbine cooling fan installed on the side of the substrate close to the air duct cover; a resonant capacitor group mounting groove is provided on the side of the substrate away from the air duct cover; an air intake window is provided on the air duct cover; and the air intake window is provided corresponding to the turbine cooling fan.

[0010] In some possible implementations, the resonant capacitor group includes a PCB board installed in a resonant capacitor group installation slot, a plurality of capacitors installed and connected to the PCB board, and output leads connected to the capacitors. The resonant capacitor group can change the series-parallel connection mode between individual capacitors to achieve a change in capacitance value, thereby achieving a suitable parameter value.

[0011] In some possible implementations, in order to effectively ensure that the magnetic plate and the coil are arranged at equal distances and to ensure parameter consistency, the isolation plate is an equidistant isolation plate and has a hollow structure.

[0012] In some possible implementations, the coil structure is a disc coil made of Litz wire; its function as the primary side is to generate a magnetic field when a high-frequency conversion current passes through it, and when it acts as the secondary side, it converts the magnetic field into a high-frequency alternating electric field.

[0013] The magnetic plate is made of manganese-zinc ferrite and is integrally cast to achieve magnetic concentration and increase the magnetic flux.

[0014] In some possible implementations, a potting isolator is further provided between the magnetic plate and the resonant capacitor group. The potting isolator is used for assembling the coil, the magnetic plate, and the isolation plate.

[0015] In some possible implementations, it also includes a shell with a mounting groove disposed on a side of the coil structure away from the isolation plate, wherein the coil structure, the isolation plate, and the magnetic plate are sequentially mounted in the mounting groove; the shell, the radiator, and the air duct cover are connected by bolts; and the coil structure is located between the isolation plate and the shell.

[0016] In some possible embodiments, in order to effectively achieve high thermal conductivity, the shell is made of a mixed ABS-GF material; the shell includes a base plate and a vertical plate installed on the base plate; the vertical plate and the base plate cooperate with each other to form a mounting groove, and a sealing groove is provided on the side of the vertical plate away from the base plate; the side of the base plate close to the base plate is provided with a protrusion that cooperates with the sealing groove.

[0017] Compared with the prior art, the present invention has the following beneficial effects:

[0018] The present invention realizes installation by stacking, and has good heat conduction effect;

[0019] The present invention has a good sealing effect through the glue filling, the cooperation of the sealing groove and the protrusion;

[0020] In the present invention, by adjusting the connection relationship between capacitors, the change of the capacitors can be effectively achieved;

[0021] The present invention has good thermal conductivity and heat dissipation performance, and can effectively reduce the heat generated by the internal resistance of the coil, eddy currents, and eddy currents induced by magnetic leakage of the heat dissipation structure. The reduction of heat can suppress the change of coil parameters and ensure the stability of the charging system. BRIEF DESCRIPTION OF THE DRAWINGS

[0022] Figure 1 An exploded view of the present invention;

[0023] Figure 2 It is a schematic diagram of the cross-sectional structure of the present invention;

[0024] Figure 3 A schematic diagram of the structure of the substrate in the present invention

[0025] Figure 4 It is a structural schematic diagram of the resonant capacitor group in the present invention;

[0026] Figure 5 It is a schematic diagram of the structure of the potting isolator in the present invention;

[0027] Figure 6 It is a schematic diagram of the structure of the housing in the present invention;

[0028] Figure 7 It is a schematic diagram of the structure of the coil in the present invention;

[0029] Among them: 1. Air duct cover; 2. Turbine cooling fan; 3. Radiator; 31. Resonant capacitor group installation slot; 32. Outlet sealing glue slot; 33. Base plate; 34. Heat dissipation teeth; 35. Protrusion; 4. Resonant capacitor group; 41. PCB board; 42. Capacitor; 43. Coil welding column; 44. Output lead; 5. Potting isolator; 6. Temperature control switch; 7. Outlet rubber terminal; 8. Magnetic plate; 9. Isolation plate; 10. Coil; 11. Housing. DETAILED DESCRIPTION

[0030] The following will be combined with the drawings in the embodiments of the present application to clearly and completely describe the technical solutions in the embodiments of the present application. Obviously, the described embodiments are part of the embodiments of the present application, not all of the embodiments. Based on the embodiments in the present application, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of this application.

[0031] The words "first", "second" and similar terms mentioned in this application do not indicate any order, quantity or importance, but are only used to distinguish different components. Similarly, words such as "one" or "an" do not indicate a quantity limitation, but indicate the existence of at least one. Words such as "connected" or "connected" are not limited to physical or mechanical connections, but may include electrical connections, whether direct or indirect.

[0032] In the implementation of this application, "and / or" describes the association relationship of associated objects, indicating that three relationships may exist. For example, A and / or B can represent three situations: A exists alone, A and B exist at the same time, and B exists alone.

[0033] In the description of the embodiments of the present application, unless otherwise specified, the meaning of "plurality" refers to two or more than two. For example, a plurality of positioning posts refers to two or more than two positioning posts.

[0034] In order to make the purpose, technical solutions and advantages of this application clearer, the technical solutions in this application will be clearly and completely described below in conjunction with the drawings in this application. Obviously, the described embodiments are part of the embodiments of this application, not all of them. Based on the embodiments in this application, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of this application.

[0035] The present invention will be further described below in conjunction with the accompanying drawings and embodiments.

[0036] The present invention is achieved through the following technical solutions: Figure 1-Figure 7 As shown,

[0037] A high-power wireless charging coil 10 structure includes a coil 10 structure, an isolation plate 9, a magnetic plate 8, a resonant capacitor group 4, and a heat dissipation structure which are stacked in sequence.

[0038] In some possible implementations, in order to effectively achieve heat dissipation, the heat dissipation structure includes an air duct cover 1 and a radiator 3 which are arranged in sequence; the radiator 3 is arranged between the resonant capacitor group 4 and the air duct cover 1.

[0039] In some possible implementations, there is a gap between the radiator 3 and the air duct cover 1, and the gap is 3-5 mm. The purpose of this arrangement is to allow air to flow in from the side.

[0040] In some possible embodiments, the radiator 3 includes a substrate 33 and a turbine cooling fan 2 installed on the side of the substrate 33 close to the air duct cover 1; a resonant capacitor group mounting groove 31 is provided on the side of the substrate 33 away from the air duct cover 1; an air intake window is provided on the air duct cover 1; and the air intake window is provided corresponding to the turbine cooling fan 2.

[0041] Preferably, a temperature control switch 6 is also installed on the side of the substrate 33. The temperature control switch 6 is connected in series with the turbo cooling fan 2. Its function is to be turned on when a preset temperature value is reached, and the turbo cooling fan 2 will be turned on.

[0042] Preferably, the turbine cooling fan 2 is installed on a substrate 33, and a groove for the turbine cooling fan 2 is provided on the substrate 33, and the distance between the turbine cooling fan 2 and the air duct cover 1 is 3 mm; the purpose of such arrangement is that when the air inlet window of the air duct cover 1 is blocked, air can flow in from the groove.

[0043] In some possible implementations, the resonant capacitor group 4 includes a PCB board 41 installed in the resonant capacitor group installation groove 31 , a plurality of capacitors 42 installed and connected on the PCB board 41 , and output leads 44 connected to the capacitors 42 .

[0044] Preferably, the resonant capacitor group 4 further includes a coil welding column 43 , and the magnetic plate 8 is provided with a mounting hole for the coil welding column 43 to be mounted in cooperation.

[0045] Preferably, the substrate 33 is also provided with an outlet sealing groove 32, and an output lead 44 connected to the capacitor 42, and the other end of the output lead 44 will pass through the outlet sealing groove 32. The outlet sealing groove 32 is used to seal the wires that need to be led out, thereby improving the protection level.

[0046] Preferably, the output end of the output lead 44 is wrapped with an output rubber terminal 7, and a circular hole connected to the output sealant groove 32 is provided on the side of the substrate 33. The output end of the output lead 44 passes through the center hole and is then wrapped with the output rubber terminal 7. The output rubber terminal 7 has the function of wrapping and protecting the output lead 44.

[0047] Preferably, the resonant capacitor group 4 can change the series-parallel connection mode between the single capacitors 42 to achieve the change of the value of the capacitor 42, thereby achieving a suitable parameter value.

[0048] Preferably, heat dissipation teeth 34 are provided on the side of the substrate 33; the heat dissipation teeth 34 increase the heat dissipation area, thereby utilizing heat exchange.

[0049] In some possible implementations, in order to effectively ensure that the magnetic plate 8 and the coil 10 are arranged at equal intervals and to ensure parameter consistency, the isolation plate 9 is an equidistant isolation plate and has a hollow structure.

[0050] The isolation plate 9 is located between the coil 10 and the magnetic plate 8, and its function is to set the magnetic plate 8 and the coil 10 at equal distances to ensure parameter consistency. In addition, it adopts a hollow structure design so that the thermal conductive potting glue can be in good contact with the coil 10 and conduct heat to the magnetic plate 8.

[0051] In some possible implementations, the coil 10 structure is a disc coil 10 made of Litz wire; its function as the primary side is to generate a magnetic field when a high-frequency conversion current passes through it, and when it acts as the secondary side, it converts the magnetic field into a high-frequency alternating electric field.

[0052] The magnetic plate 8 is made of manganese-zinc ferrite through integral casting to achieve magnetic concentration and increase the magnetic flux.

[0053] In some possible implementations, a potting isolator 5 is further provided between the magnetic plate 8 and the resonant capacitor group 4. The potting isolator 5 is used for assembling the coil 10, the magnetic plate 8, and the isolation plate 9.

[0054] In some possible implementations, the outer shell 11 is provided with a mounting groove and is arranged on the side of the coil 10 structure away from the isolation plate 9. The coil 10 structure, the isolation plate 9, and the magnetic plate 8 are sequentially installed in the mounting groove; the outer shell 11, the radiator 3, and the air duct cover 1 are connected by bolts; and the coil 10 structure is located between the isolation plate 9 and the outer shell 11.

[0055] Preferably, a groove is provided on one side of the potting isolator 5 away from the resonant capacitor group 4, the magnetic plate 8, the isolation plate 9, and one side of the coil 10 are installed in the groove, and the potting isolator 5 is installed in the installation groove;

[0056] Preferably, the potting isolator 5 is installed in the mounting groove, and the height of the potting isolator 5 is 1 mm less than the height of the mounting groove; such an arrangement will result in a gap between the magnetic plate 8 and the heat dissipation structure, reducing the eddy current effect caused by leakage magnetic field acting on the heat dissipation structure.

[0057] In some possible embodiments, in order to effectively achieve high thermal conductivity, the shell 11 is made of a mixed ABS-GF material; the shell 11 includes a bottom plate and a vertical plate installed on the bottom plate; in order to effectively improve the sealing effect of the present invention; the vertical plate and the bottom plate cooperate with each other to form a mounting groove, and a sealing groove is provided on the side of the vertical plate away from the bottom plate; the side of the substrate 33 close to the bottom plate is provided with a protrusion 35 installed in cooperation with the sealing groove.

[0058] In some possible implementations, an assembly groove is provided on one side of the potting isolator 5 close to the housing 11 , and the assembly groove is used for assembling the coil 10 , the magnetic plate 8 , and the isolation plate 9 .

[0059] The housing 11 is mainly used for packaging, and is made of a high-heat-conductivity, high-strength mixed ABS-GF material. A sealing groove is provided for installing a sealing strip, and cooperates with the protrusion 35 on the substrate 33 to form an effective sealing structure.

[0060] Reinforcing ribs are arranged on the bottom plate to support the coil 10 and other structures, thereby reducing thermal resistance and facilitating the dissipation of part of the heat through the housing 11; threaded holes are arranged on the vertical plate, and the base plate 33 is screwed to the vertical plate.

[0061] The assembly method is:

[0062] First, install the turbo cooling fan 2 on the substrate 33, insert the lead wire of the turbo cooling fan 2 into the outlet wire sealing groove 32, and apply glass glue on the insertion point, and connect the lead wire of the turbo cooling fan 2 to the temperature control switch 6 in series;

[0063] Connect the air duct cover 1 and the base plate 33 by bolts to form an air duct;

[0064] Install the well-proportioned resonant capacitor group 4 in the resonant capacitor group installation slot 31;

[0065] Place the potting isolator 5 on the resonant capacitor group 4, reduce the potting glue fixing treatment of the potting isolator 5, so that the thickness of the potting glue is 1mm higher than the bottom plate of the potting isolator; during the potting process, continuously shake it to allow the air in the colloid to escape, reduce the parasitic capacitance 42 generated by the air bubbles formed, and when the potting glue has not started to solidify, press the magnetic plate 8 tightly on the potting of the isolator, and then wait for the potting glue to solidify;

[0066] Place the equidistant isolation plate on the magnetic plate 8, perform a glue filling process, the glue filling thickness is equivalent to the thickness of the equidistant magnetic plate 8, and then wait for the glue to solidify;

[0067] Place the coil 10 on the equidistant isolation plate, and weld the two ends of the coil 10 to the coil welding posts 43 on the resonant capacitor group 4. When welding, the insulating layer of the Litz wire must be welded, and sufficient tin must be added when welding with the welding point to ensure that it can be welded through to prevent the problem of excessive resistance and heating caused by cold welding;

[0068] After welding, the coil 10 is filled with glue. This time, the glue should be flush with the potting isolator 5, and the glue is allowed to solidify.

[0069] Put the sealing strip into the sealing groove of the housing 11, and apply glass silicone on both sides of the sealing press of the radiator 3; fit the front housing 11 onto the radiator 3, and insert the connecting screw into the threaded hole of the housing 11, and screw it to fix it with the rear radiator 3;

[0070] Assembly is complete.

[0071] The embodiments of the present application are introduced in detail above. Specific examples are used in the present application to illustrate the principles and implementation methods of the present application. The description of the above embodiments is only used to help understand the method and core idea of ​​the present application. At the same time, for general technical personnel in the field, according to the idea of ​​the present application, there will be changes in the specific implementation methods and application scope. In summary, the content of this specification should not be understood as a limitation on the present application.

Claims

1. A medium to high power wireless charging coil structure, characterized in that: It includes a coil structure, an isolation plate, a magnetic plate, a resonant capacitor group, a heat dissipation structure, and a housing provided with a mounting groove on a side of the coil structure away from the isolation plate; the heat dissipation structure includes an air duct cover and a radiator provided in sequence; the radiator is provided between the resonant capacitor group and the air duct cover; A potting isolator is also provided between the magnetic plate and the resonant capacitor group; The coil structure is located between the isolation plate and the outer shell; the coil structure, isolation plate, and magnetic plate are installed in the mounting groove in sequence; the outer shell, radiator, and air duct cover are connected by bolts; a groove is provided on the side of the potting isolator away from the resonant capacitor group, and the magnetic plate, isolation plate, and one side of the coil are installed in the groove; the potting isolator is installed in the mounting groove, and the height of the potting isolator is less than the height of the mounting groove by 1 mm.

2. A medium to high power wireless charging coil structure according to claim 1, characterized in that: There is a gap between the radiator and the air duct cover, and the gap is 3-5 mm.

3. A medium to high power wireless charging coil structure according to claim 2, characterized in that: The radiator includes a substrate and a turbine cooling fan installed on the side of the substrate close to the air duct cover; a resonant capacitor group mounting groove is provided on the side of the substrate away from the air duct cover; an air intake window is provided on the air duct cover; and the air intake window is provided corresponding to the turbine cooling fan.

4. The medium-to-high power wireless charging coil structure according to claim 3, characterized in that: The resonant capacitor group includes a PCB board installed in a resonant capacitor group installation groove, a plurality of capacitors installed and connected on the PCB board, and output leads connected to the capacitors.

5. A medium-to-high power wireless charging coil structure according to any one of claims 1 to 4, characterized in that: The isolation plates are equidistant isolation plates and have a hollow structure.

6. A medium-to-high power wireless charging coil structure according to any one of claims 1 to 4, characterized in that: The coil structure is a disc coil made of Litz wire; the magnetic plate is made of manganese-zinc ferrite through integrated casting.

7. The medium-to-high power wireless charging coil structure according to claim 4, characterized in that: The shell is made of mixed ABS-GF material, and includes a bottom plate and a vertical plate installed on the bottom plate; the vertical plate and the bottom plate cooperate with each other to form a mounting groove, and a sealing groove is provided on the side of the vertical plate away from the bottom plate; a protrusion that cooperates with the sealing groove is provided on the side of the base plate close to the bottom plate.

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