A coil structure for wireless charger

Abstract

The present invention discloses a coil structure for a wireless charger and an electronic device, wherein the coil structure comprises a plurality of coils, wherein the plurality of coils are stacked into a plurality of coil layers, wherein at least two electronic devices can be placed above the plurality of coils to charge the at least two electronic devices.

Description

Technical Field

[0001] The present invention relates to a plurality of coil structures, and in particular to a plurality of coil structures for wireless charging. Background Art

[0002] As wireless charging of consumer and automotive electronic devices becomes more common, there are some limitations on placing the electronic device on the coil of the wireless charger that charges the electronic device. In addition, as speed becomes more and more important, heat dissipation of the wireless charger also becomes an issue. The present invention relates to multiple coil structures, and more particularly to multiple coil structures for wireless charging.

[0003] Therefore, the present invention proposes a solution to overcome the above problems. Summary of the invention

[0004] An object of the present invention is to provide a coil structure for a wireless charger to allow at least two electronic devices to be wirelessly charged simultaneously.

[0005] An object of the present invention is to provide a structure of a coil for a wireless charger to allow an electronic device to be placed in different orientations for charging.

[0006] An object of the present invention is to provide a wireless charger having a metal housing unit to better withstand stress, thereby protecting a coil of the wireless charger and reducing the size of the wireless charger.

[0007] An object of the present invention is to provide a wireless charger having a metal housing unit and a fan to generate airflow in multiple directions to better dissipate heat of the wireless charger.

[0008] In one embodiment, a coil structure for a wireless charger is disclosed, wherein the coil structure includes a plurality of coils, wherein the plurality of coils are stacked into at least two coil layers, wherein at least two electronic devices can be placed above the plurality of coils to charge the at least two electronic devices.

[0009] In one embodiment, the two electronic devices are placed above the plurality of coils in a vertical direction to charge the at least two electronic devices.

[0010] In one embodiment, a plurality of coils are stacked into three layers, each layer including at least two coils, to form a magnetic flux effective area for charging electronic devices.

[0011] In one embodiment, multiple coils can be divided into multiple groups for charging.

[0012] In one embodiment, the plurality of coils includes eighteen coils stacked in three layers, wherein a bottom layer includes seven coils, a middle layer includes four coils, and a top layer includes seven coils.

[0013] In one embodiment, the plurality of coils are stacked in two layers, wherein the bottom layer includes four coils and the top layer includes five coils.

[0014] In one embodiment, each of the two electronic devices being charged is a mobile phone.

[0015] In one embodiment, a coil structure for a wireless charger is disclosed, wherein the coil structure includes a plurality of coils, wherein the plurality of coils are stacked into a plurality of coil layers, wherein an electronic device can be placed above the plurality of coils in at least three different orientations to charge the electronic device.

[0016] In one embodiment, an electronic device is disclosed, wherein the electronic device includes: a metal shell unit, including a metal plate, a first recessed portion formed on the upper side of the metal shell unit and a second recessed portion formed on the lower side of the metal shell unit, wherein the first recessed portion and the second recessed portion are located on opposite sides of the metal plate; at least one conductive element is disposed in the first recessed portion; and a circuit board is disposed in the second recessed portion and electrically connected to the at least one conductive element.

[0017] In one embodiment, the electronic device is a wireless charger, wherein the at least one conductive element comprises a plurality of coils, wherein the plurality of coils are stacked in multiple layers to charge at least one electronic device.

[0018] In one embodiment, a plurality of coils are disposed in the first recess.

[0019] In one embodiment, the circuit board has a through hole, wherein at least a portion of a fan is disposed in the through hole.

[0020] In one embodiment, an EMI filter is disposed over the plurality of coils.

[0021] In one embodiment, a plastic cover is placed over the EMI filter.

[0022] In one embodiment, a metal cover covers the circuit board, wherein the plastic cover and the metal cover are on two opposite sides of the metal plate.

[0023] In one embodiment, the metal housing unit comprises aluminum or aluminum alloy material.

[0024] In one embodiment, the metal plate includes a die-cast aluminum alloy (ADC12), that is, the metal plate can have strong mechanical strength to withstand the stress when the wireless charger is under pressure, and the die-cast aluminum alloy (ADC12) includes an Al-Si-Cu alloy.

[0025] In one embodiment, a fan is located at a corner of the metal housing unit, wherein the fan causes airflow from a first side of the metal housing unit to enter a second side of the metal housing unit, wherein the first side and the second side are two adjacent sides of the metal housing unit.

[0026] In one embodiment, the fan causes airflow from a first opening on a first side of the metal housing unit and a second opening on a second side of the metal housing unit, wherein the first opening and the second opening are on opposite sides of the metal plate. BRIEF DESCRIPTION OF THE DRAWINGS

[0027] The accompanying drawings are included to provide a further understanding of the invention and are incorporated in and constitute a part of this specification. The drawings illustrate embodiments of the invention and together with the description serve to explain the principles of the invention.

[0028] Figure 1A A top view showing the structure of a coil for a wireless charger in one embodiment of the present invention.

[0029] Figure 1B A top view of the effective area of ​​magnetic flux generated by a charging coil in one embodiment of the present invention is shown.

[0030] Figure 1C The figure shows a position of an electronic device above a charging coil according to an embodiment of the present invention.

[0031] Figure 1D The figure shows a position of an electronic device above a charging coil according to an embodiment of the present invention.

[0032] Figure 1E The figure shows a position of an electronic device above a charging coil according to an embodiment of the present invention.

[0033] Figure 1F The figure shows a position of an electronic device above a charging coil according to an embodiment of the present invention.

[0034] Figure 1G The figure shows a position of an electronic device above a charging coil according to an embodiment of the present invention.

[0035] Figure 1H The figure shows a position of a receiving coil of an electronic device above a charging coil in one embodiment of the present invention.

[0036] Figure 2A A bottom layer with four coils in one embodiment of the invention is shown.

[0037] Figure 2B A top layer with five coils in one embodiment of the invention is shown.

[0038] Figure 3A An exploded view of a wireless charger in one embodiment of the present invention is shown.

[0039] Figure 3B An exploded view from above of a wireless charger in one embodiment of the present invention is shown.

[0040] Figure 3C An exploded view from below of a wireless charger in one embodiment of the present invention is shown.

[0041] Figure 3D The airflow in a wireless charger caused by a fan in one embodiment of the present invention is shown.

[0042] Figure 3E The airflow at the side surface of the wireless charger in one embodiment of the present invention is shown.

[0043] Explanation of the reference numerals: 101 - wireless charger; 102, 103, 104 - coil layer; 102a, 103a, 104a - coil; 200, 201 - electronic device; 200a, 201a - receiving coil; 1, 2, 3 - horizontal line or vertical line; D1, D2 - diagonal line; 351 - upper cover; 352 - EMI filter; 353 - coil; 354 ​​- metal housing unit; 356a - through hole; 310a, 310b - airflow; 101g, 101h, 101m, 101n - opening; 354d - first side; 354e - second side; 356 - fan; 357 - circuit board; 358 - lower cover. DETAILED DESCRIPTION

[0044] It should be understood that many different embodiments or examples for implementing different features of the present invention are provided below. The specific examples of the following devices and settings are used to simplify the present invention. Of course, these are only examples and are not intended to limit the present invention. For example, in the following description, the formation of a first feature on or on a second feature may include an embodiment in which the first feature and the second feature are formed in direct contact, and may also include an embodiment in which an additional feature is formed between the first feature and the second feature, so that the first feature and the second feature are not in direct contact. In addition, the present invention may repeat reference numbers and / or letters in various examples. These repetitions are for the purpose of simplification and clarity, and do not themselves indicate the relationship between the various embodiments and / or configurations discussed.

[0045] The invention discloses a wireless charger having a plurality of stacked coil layers for charging an electronic device, wherein the plurality of coil layers form a magnetic flux effective area for charging.

[0046] For user convenience, the electronic device does not need to be fixed in a specific direction or alignment over the multiple coil layers of the stack to charge the electronic device.

[0047] FIG1 shows a top view of a coil structure for a wireless charger 101 according to an embodiment of the present invention, wherein the coil structure includes a plurality of coils, and the plurality of coils are stacked into a plurality of coil layers 102, 103, 104, wherein each coil layer includes at least two coils. Figure 1C , Figure 1D , Figure 1E and Figure 1F , wherein at least two electronic devices 200 , 201 can be placed at different positions above the multiple layers 102 , 103 , 104 of the coil to charge the at least two electronic devices 200 , 201 .

[0048] like Figure 1B As shown, multiple coil layers 102, 103, 104 form a magnetic flux effective area 105 for charging the electronic device. Figure 1C , Figure 1D , Figure 1E and Figure 1F , the receiving coils 200a, 201a of the electronic devices 200, 201 can be placed in the magnetic flux effective area 105 to be charged through the coupling induction between the transmitting coils and the receiving coils 200a, 201a of the multiple coil layers 102, 103, 104, without being restricted by the placement direction of the electronic devices 200, 201.

[0049] In one embodiment, please refer to Figure 1C , Figure 1D , Figure 1E and Figure 1F The two electronic devices 200, 201 can be placed above the plurality of coil layers 102, 103, 104 in at least two different orientations to charge the two electronic devices 200, 201. For example, the electronic device 200 can be placed in a vertical direction, such as Figure 1C As shown, a horizontal placement, such as Figure 1D As shown; the electronic device 201 can be placed in a vertical direction, such as Figure 1E As shown, a horizontal placement, such as Figure 1F shown.

[0050] In one embodiment, two electronic devices can be placed over the coil in at least three different orientations to charge the two electronic devices.

[0051] In one embodiment, an electronic device can be placed above the coil in a horizontal, vertical, or diagonal orientation to charge the electronic device.

[0052] like Figure 1G As shown, the electronic devices can be placed in a diagonal direction.

[0053] In one embodiment, the electronic device is a mobile phone.

[0054] In one embodiment, Figure 1H As shown, when the receiving coil 200a of the electronic device 200 is located between the three coils 102a, 103a, 104a of the plurality of coil layers 102, 103, 104, a coil with a higher K coupling among the three coils 102a, 103a, 104a will be selected to charge the electronic device 200. In one embodiment, the top coil 102a among the three coils 102a, 103a, 104a will be selected because the receiving coil 200a of the electronic device 200 and the top coil 102a are the shortest distance apart and thus have a better coupling coefficient.

[0055] In one embodiment, the wireless charger 101 includes at least one processor or microcontroller to select a transmitting coil having a higher K coupling with the receiving coil 200 a of the electronic device 200 .

[0056] In one embodiment, please refer to Figure 2A and Figure 2B , the plurality of coils are stacked into two coil layers, wherein the bottom layer includes four coils and the top layer includes five coils.

[0057] In one embodiment, Figure 2A As shown, the four coils of the bottom layer are placed in the four spaces formed by the two diagonal lines D1 and D2, and the five coils of the top layer are placed on the two diagonal lines D1 and D2, as shown in FIG. Figure 2B As shown, each horizontal line H1, H2, H3 or each vertical line V1, V2, V3 or each diagonal line D1, D2 passes through three coils.

[0058] In one embodiment, the plurality of coils are stacked into three coil layers, and each coil layer includes at least four coils.

[0059] In one embodiment, the plurality of coils can be divided into two groups, each group including a plurality of coils.

[0060] In one embodiment, the plurality of coils can be divided into two groups, each group including nine coils.

[0061] In one embodiment, the plurality of coils includes eighteen coils stacked in three layers, wherein a bottom layer includes seven coils, a middle layer includes four coils, and a top layer includes seven coils.

[0062] In one embodiment, each of the electronic devices 200, 201 is a mobile phone.

[0063] Figure 3A is a perspective view of the wireless charger 101 . Figure 3B An exploded view of the wireless charger 101 from above. Figure 3C An exploded bottom view of the wireless charger 101 .

[0064] like Figures 3A-3C As shown, the wireless charger 101 includes: a metal housing unit 354, which includes a metal plate, a first recessed portion formed on the upper side of the metal housing unit 354, and a second recessed portion formed on the lower side of the upper side of the metal housing unit 354. The metal housing unit 354, wherein the first recessed portion and the second recessed portion are located on opposite sides of the metal plate, wherein at least one conductive element, such as a coil 353, is disposed in the first recessed portion; and a circuit board 357 is disposed in the second recessed portion and is electrically connected to the at least one conductive element, such as the coil 353.

[0065] In one embodiment, the at least one conductive element includes a plurality of coils 353 , wherein the plurality of coils 353 are stacked into a plurality of coil layers for charging at least one electronic device, and the plurality of coil layers are disposed in the first recess.

[0066] In one embodiment, the circuit board 357 has a through hole 356 a , wherein at least a portion of the fan 356 is disposed in the through hole 356 a .

[0067] In one embodiment, the fan 356 is located at a corner of the metal housing unit 354, wherein the fan 356 causes airflow to enter the second side 354e of the metal housing unit from the first side 354d of the metal housing unit 354, wherein the first side 354d and the second side 354e are two adjacent sides of the metal housing unit 354. Figure 3D .

[0068] Please refer to Figure 3D, wherein at least a portion of the fan 356 is disposed below the circuit board 357, wherein the fan 356 allows airflows 310a, 310b to enter through the openings 101g, 101h, 101m, 101n at the first side 354d of the wireless charger 101 and flow to the second side 354e of the wireless charger 101, wherein the first side 354d and the second side 354e are two adjacent sides of the wireless charger 101, wherein the openings 101g, 101m can form an airflow path above the circuit board 357, and the openings 101h, 101n can form an airflow path below the circuit board 357.

[0069] Please refer to Figure 3E , which shows a side view of the airflow at the second side 354e. The fan 356 causes the airflow 301c to enter the second side 354e, and the airflow 310d to leave the second side 354e. In this way, the heat generated by the wireless charger 101 can be dissipated through multiple paths, one path above the circuit board 357 and another path below the circuit board 357, thereby more effectively reducing the temperature of the wireless charger 101.

[0070] In one embodiment, at least one heat sink extends along the metal housing unit 354 in the direction of air flow.

[0071] In one embodiment, the EMI filter 352 is disposed above the plurality of coils 353 .

[0072] In one embodiment, the upper cover 351 , which may be a plastic cover, is disposed above the EMI filter 352 .

[0073] In one embodiment, a lower cover 358 , which may be a metal cover, is disposed on the bottom surface of the circuit board 357 , wherein the upper cover 351 and the lower cover 358 are on two opposite sides of the metal plate 354 a .

[0074] In one embodiment, the plurality of coils 353 are stacked into a plurality of coil layers, wherein each coil layer includes at least two coils, wherein at least two electronic devices can be placed over the plurality of coil layers in at least two different directions to charge the at least two electronic devices.

[0075] In one embodiment, the plurality of coils 353 includes eighteen coils stacked in three layers, wherein the bottom layer includes seven coils, the middle layer includes four coils, and the top layer includes seven coils.

[0076] In one embodiment, the metal plate includes ADC 12 .

[0077] In one embodiment, the metal housing unit 354 includes aluminum or an aluminum alloy material.

[0078] In one embodiment, the plurality of fins are located on an inner surface or an outer surface of the metal housing unit 354 , and the plurality of fins extend along the metal housing unit 354 in a direction of airflow caused by the fan 356 .

[0079] In one embodiment, the surface of the plurality of fins may be roughened.

[0080] In one embodiment, the air inlet is substantially parallel to the air outlet, and the wireless charger may be configured with a filter for filtering air from the air inlet. In one embodiment, the filter may be made of a hydrophobic material.

[0081] In one embodiment, the wireless charger 101 further includes a fan speed controller that can adjust the rotation speed of the fan based on the temperature of the wireless charger 101 or the electronic device 200 , 201 .

[0082] In one embodiment, a magnetic material encapsulates the coil, wherein the magnetic material can be a metal or alloy magnetic material or a ferrite magnetic material. The ferrite magnetic material can be polycrystalline, single crystal or amorphous.

[0083] In one embodiment, the surface of the metal housing unit 354 and the coil 353 are sealed by a ferrite magnetic material.

[0084] In one embodiment, the metal housing unit 354 is sealed with the upper cover 351 and the lower cover 358 by a ferrite magnetic material.

[0085] In one embodiment, the bottom surface of the upper cover 351 and each of the coils 353 may be in contact with the ferrite magnetic material to transfer stress, wherein the upper cover 351 , the coils 353 , and the ferrite magnetic material are supported by a metal plate of the metal housing unit 354 .

[0086] From the foregoing, it can be understood that although specific embodiments have been described herein for illustrative purposes, various modifications may be made without departing from the spirit and scope of the present invention. In addition, where alternatives are disclosed for a particular embodiment, the alternatives may also be applied to other embodiments, even without particular description.

Claims

1. A wireless charger, characterized in that: It includes a metal shell, a coil structure configured in the metal shell and an upper cover located above the coil structure, wherein the coil structure includes a plurality of coils, wherein the plurality of coils are stacked into at least two layers of coils, wherein each layer of coils includes at least two coils, wherein at least two electronic devices can be placed above the plurality of coils to charge the at least two electronic devices, wherein the plurality of coils are covered with ferrite magnetic material, wherein the lower surface of the upper cover and the upper surface of the plurality of coils are in contact with the ferrite magnetic material, wherein the upper cover, the plurality of coils and the ferrite magnetic material are supported by a metal plate of the metal shell, wherein the metal plate includes an aluminum-silicon-copper alloy.

2. The wireless charger according to claim 1, characterized in that: The two electronic devices are placed above the plurality of coils in a horizontal direction to charge the at least two electronic devices.

3. The wireless charger according to claim 1, characterized in that: The two electronic devices are placed above the plurality of coils in a vertical direction to charge the at least two electronic devices.

4. The wireless charger according to claim 1, characterized in that: The plurality of coils are stacked into three layers of coils, wherein each layer of coils includes at least two coils, so as to charge the at least two electronic devices.

5. The wireless charger according to claim 1, characterized in that: The plurality of coils includes eighteen coils stacked in three layers, wherein a bottom layer includes seven coils, a middle layer includes four coils, and a top layer includes seven coils.

6. The wireless charger according to claim 1, characterized in that: The plurality of coils are stacked in two layers, wherein the bottom layer includes four coils and the top layer includes five coils.

7. The wireless charger according to claim 1, characterized in that: Each of the two electronic devices is a mobile phone.

8. A wireless charger, characterized in that: It includes a metal shell, a coil structure configured in the metal shell and an upper cover located above the coil structure, wherein the coil structure includes a plurality of coils, wherein the plurality of coils are stacked into multiple layers, wherein each layer includes at least two coils, wherein an electronic device can be placed above the plurality of coils in at least three different directions to charge the electronic device, wherein the plurality of coils are covered with ferrite magnetic material, wherein the lower surface of the upper cover and the upper surface of the plurality of coils are in contact with the ferrite magnetic material, wherein the upper cover, the plurality of coils and the ferrite magnetic material are supported by a metal plate of the metal shell, wherein the metal plate includes an aluminum-silicon-copper alloy.

9. The wireless charger according to claim 8, characterized in that: The electronic device can be placed above the plurality of coils in a horizontal, vertical or diagonal direction to charge the electronic device.

10. The wireless charger according to claim 8, characterized in that: The electronic device is a mobile phone.

11. A wireless charger, characterized in that: include: A metal housing unit, comprising a metal plate, a first recessed portion formed on an upper side of the metal housing unit and a second recessed portion formed on a lower side of the metal housing unit, wherein the first recessed portion and the second recessed portion are located on opposite sides of the metal plate; A plurality of coils are disposed in the first recessed portion; as well as A circuit board is arranged in the second recessed portion and electrically connected to the multiple coils, wherein the multiple coils are covered with ferrite magnetic material, wherein the lower surface of the upper cover and the upper surface of the multiple coils are in contact with the ferrite magnetic material, wherein the upper cover, the multiple coils and the ferrite magnetic material are supported by the metal plate of the metal shell, and the metal plate includes an aluminum-silicon-copper alloy.

12. The wireless charger according to claim 11, characterized in that: The circuit board has a through hole, wherein a first portion of the fan is disposed in the through hole, and a second portion of the fan is disposed below the circuit board.

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