Wireless charging module

Abstract

A wireless charging module comprises a module shell, a fan, a coil assembly and a circuit board. The module housing defines a first cavity and a second cavity, and has a first side and a second side opposite to the first side. The fan is arranged on the first side of the module shell and used for forming airflow, and an air outlet is defined on the second side of the module shell. The coil assembly is arranged in the first cavity so as to form a first air channel enabling air flow S to pass through the first surface of the coil assembly. The circuit board is configured to be located in the second cavity, so that a second air channel enabling the airflow S to pass through the first surface of the circuit board is formed, and a third air channel enabling the airflow S to pass through the second surface of the circuit board is formed. The airflow S passes through the first air duct, the second air duct and the third air duct and flows out of the wireless charging module from the air outlet.

Description

Technical Field

[0001] The present invention relates to a charging module for charging an electronic device, and in particular to a wireless charging module for charging an electronic device. Background Art

[0002] As consumer products supporting wireless charging become more and more widespread, the demand for wireless charging modules that support high-wattage (e.g. >15W) fast charging in automotive products is also rising. Therefore, the market has a strong demand for an increase in the charging area (Activearea) and heat dissipation during high-wattage charging.

[0003] Generally speaking, operating temperature is the main key factor affecting the service life of electronic components. According to the thermal simulation diagram of existing wireless charging modules, heat will be concentrated in specific hot spots, which may have a negative impact on the life of electronic components and may cause a decrease in charging power. For example, coils, magnetic cores (Ferrite), electronic components, etc. may generate high heat due to loss, which in turn affects the reliability and life of the components. Summary of the invention

[0004] According to one embodiment of the present invention, a wireless charging module is provided, which is used to charge an electronic device. According to another embodiment of the present invention, a wireless charging module is provided, which is used to charge an electronic device and includes a first air duct, a second air duct and a third air duct for dissipating heat from components of the wireless charging module.

[0005] According to one embodiment of the present invention, a wireless charging module is provided, which includes a module housing, at least one fan, a coil assembly and a circuit board. The module housing defines a first cavity and a second cavity, and has a first side and a second side relative to the first side, wherein the second side defines an air outlet. At least one fan is disposed on the first side of the module housing to form an airflow S. The coil assembly is used to generate electromagnetic induction and is disposed in the first cavity to form a first air duct that allows the airflow S to pass through the first surface of the coil assembly. The circuit board is configured to be located in the second cavity to form a second air duct that allows the airflow S to pass through the first surface of the circuit board, and to form a third air duct that allows the airflow S to pass through the second surface of the circuit board. The airflow S passes through the first air duct, the second air duct and the third air duct, and flows out of the wireless charging module from the air outlet.

[0006] In one embodiment, the second air duct is located between the first air duct and the third air duct.

[0007] In one embodiment, the circuit board includes at least one first electronic component and at least one second electronic component, wherein the heat generated by the at least one first electronic component is greater than the heat generated by the at least one second electronic component, and the at least one first electronic component is located closer to the middle of the circuit board than the at least one second electronic component.

[0008] In one embodiment, the module housing includes an upper cover, a housing body and a lower cover. The housing body has a middle partition. The first air duct is formed between the middle partition and the upper cover, the second air duct is formed between the middle partition and the circuit board, and the third air duct is formed between the circuit board and the lower cover.

[0009] In one embodiment, the distance between the middle partition and the circuit board is smaller than the distance between the circuit board and the lower cover.

[0010] In one embodiment, the wireless charging module further comprises a ferrite element. The ferrite element is located below the coil assembly, and the coil assembly and the ferrite element are tightly bonded to the middle partition of the module housing.

[0011] In one embodiment, the coil assembly includes a first coil, a second coil and a third coil. The left side of the first coil covers the right side of the second coil, and the left side of the second coil covers the right side of the third coil. In one embodiment, preferably, the first coil, the second coil and the third coil are windings made of single-strand or multi-strand enameled stranded wire.

[0012] In one embodiment, the fan blades are made of high molecular weight polymer or metal, and the fan is speed-regulated by pulse-width modulation (PWM) to control the noise generated by the wireless charging module within a specific range.

[0013] In one embodiment, the upper cover is an EMI board, and the lower cover is a metal plate. The module housing further has a third side and a fourth side, the third side is opposite to the fourth side, and the third side and the fourth side both extend between the first side and the second side.

[0014] In one embodiment, the wire material of the winding includes a self-adhesive wire containing a self-adhesive layer. In one embodiment, preferably, the material of the magnetic core element includes at least one magnetic material selected from the group consisting of manganese-zinc ferrite, nickel-zinc ferrite, ferrite and nanocrystal, and the magnetic core element is made by sintering or ceramic injection molding.

[0015] In one embodiment, the module housing is made of metal or plastic and is made by stamping, die-casting, injection molding, or machining. In one embodiment, preferably, the at least one first electronic component and the at least one second electronic component include at least one of an NFC component, an NTC thermistor, a 5G antenna, a FAKRA connector, or an EMI shielding pattern.

[0016] According to an embodiment of the present invention, since the wireless charging module includes the first air duct, the second air duct and the third air duct, the components of the wireless charging module can be cooled more efficiently. The air ducts can form effective spatial convection and effectively cool the components. BRIEF DESCRIPTION OF THE DRAWINGS

[0017] Figure 1 FIG. 4 is an exploded view of a wireless charging module according to an embodiment of the present invention.

[0018] Figure 2 FIG. 4 is a three-dimensional diagram of a wireless charging module according to an embodiment of the present invention.

[0019] Figure 3 FIG. 4 is a perspective view of a side cross-section of a wireless charging module according to an embodiment of the present invention.

[0020] Figure 4 The table is a comparison of thermal simulation temperatures of different components when wireless charging is performed on an electronic device using a wireless charging module with a fan according to an embodiment of the present invention and a wireless charging module without a fan.

[0021] Figure 5 The table compares the thermal simulation temperatures at different locations on the outer side of the wireless charging module when wirelessly charging an electronic device using a wireless charging module with a fan according to an embodiment of the present invention and a wireless charging module without a fan.

[0022] Fig. 6A A simulation diagram of the flow field of a wireless charging module according to an embodiment of the present invention is shown.

[0023] Figure 6B A table showing the air flow in each air duct of a wireless charging module according to an embodiment of the present invention.

[0024]

Explanation of symbols

[0025] 100: Wireless charging module

[0026] 110: Module housing

[0027] 111: First side

[0028] 112: Second side

[0029] 113: Third side

[0030] 114: The fourth side

[0031] 115: Upper cover

[0032] 116: Shell body

[0033] 117: Lower cover

[0034] 118: Middle partition

[0035] 119: Air outlet

[0036] 120: Fan

[0037] 121: First cavity

[0038] 122: Second cavity

[0039] 130: Coil assembly

[0040] 131: First coil

[0041] 132: Second coil

[0042] 133: The third coil

[0043] 134: Fourth coil

[0044] 135: Magnetic core components

[0045] 140: Circuit board

[0046] 141: First Electronic Components

[0047] 142: Second electronic component

[0048] 191: First Wind Channel

[0049] 192: Second Wind Channel

[0050] 193: The Third Wind Channel

[0051] S: Airflow DETAILED DESCRIPTION

[0052] Figure 1 An exploded view of a wireless charging module according to an embodiment of the present invention is shown. Figure 2 A three-dimensional diagram showing a wireless charging module according to an embodiment of the present invention. Figure 3 A perspective view showing a side cross-section of a wireless charging module according to an embodiment of the present invention.

[0053] According to an embodiment of the present invention, Figures 1 to 3As shown, the wireless charging module 100 includes: a module housing 110, at least one fan 120, a coil group 130 and a circuit board 140. The module housing 110 defines a first cavity 121 and a second cavity 122, and has a first side 111 and a second side 112 relative to the first side 111, and the second side 112 defines an air outlet 119. In this embodiment, the number of fans 120 is illustrated as one as an example. The fan 120 is disposed on the first side 111 of the module housing 110 to form an air flow S. The circuit board 140 can be a printed circuit board assembly (PCBA, Printed Circuit Board Assembly). The printed circuit board assembly includes the main electronic components of the wireless charging module 100, and the heat generated by the electronic components is mainly dissipated to the outside of the wireless charging module 100 through thermal convection.

[0054] The coil assembly 130 is used to generate electromagnetic induction and is disposed in the first cavity 121 to form a first air duct 191 through which the airflow S passes through the first surface of the coil assembly 130. The second surface of the coil assembly 130 faces the module housing 110 and defines a surface of the first cavity 121. Figures 2 to 3 As shown, the circuit board 140 is configured to be located in the second cavity 122, so as to form a second air duct 192 for the air flow S to pass through the first surface of the circuit board 140, and to form a third air duct 193 for the air flow S to pass through the second surface of the circuit board 140. The air flow S passes through the first air duct 191, the second air duct 192 and the third air duct 193, and flows out of the wireless charging module 100 from the air outlet 119. In this embodiment, the second air duct 192 is located between the first air duct 191 and the third air duct 193, and Figure 2 In the embodiment of the present invention, the first surface of the circuit board 140 is an upper surface, and the second surface of the circuit board 140 is a lower surface.

[0055] In one embodiment, if Figure 1 As shown, the module housing 110 includes an upper cover 115, a housing body 116 and a lower cover 117. The housing body 116 has a middle partition 118, a first air duct 191 is formed between the middle partition 118 and the upper cover 115, a second air duct 192 is formed between the middle partition 118 and the circuit board 140, and a third air duct 193 is formed between the circuit board 140 and the lower cover 117. The present invention does not limit the manufacturing method and material of the module housing 110. In one embodiment, the material of the module housing 110 can be a metal or plastic material. In one embodiment, the module housing 110 can be made by stamping, die casting, injection molding, or processing with a processing machine.

[0056] The second surface of the coil assembly 130 faces the middle partition 118, and the airflow S passes through the first surface of the coil assembly 130 (at Figure 1 In one embodiment, the wireless charging module 100 further includes a magnetic core element (Ferrite) 132, which is located below the coil assembly 130, and the coil assembly 130 and the magnetic core element 132 are bonded as tightly as possible to the middle partition 118 of the module housing 110. In one embodiment, the material of the magnetic core element 132 includes manganese-zinc ferrite, nickel-zinc ferrite, ferrite or nanocrystalline magnetic material, and the magnetic core element 132 is made by sintering or ceramic injection molding.

[0057] In one embodiment, the upper cover 115 may be an EMI board (Electromagnetic interference board), which is a circuit board used to reduce electromagnetic interference (EMI) generated by electronic equipment and resist external EMI interference. The lower cover 117 is a metal plate to increase the heat dissipation effect. The module housing 110 further has a third side 113 and a fourth side 114, the third side 113 is opposite to the fourth side 114, and the third side 113 and the fourth side 114 both extend between the first side 111 and the second side 112. In one embodiment, no through hole is defined on the third side 113 and the fourth side 114. Since the fan 120 is disposed on the first side 111 of the module housing 110, and the second side 112 defines an air outlet 119, the air flow S flows in from the first side 111 and then flows out from the air outlet 119 of the second side 112, forming an air flow field for heat dissipation.

[0058] In one embodiment, the coil assembly 130 includes a first coil 131, a second coil 132, and a third coil 133. Figure 1 From the perspective shown, the left side of the first coil 131 covers the right side of the second coil 132, and the left side of the second coil 132 covers the right side of the third coil 133. Preferably, the coil assembly 130 may further include a fourth coil 134, and the left side of the third coil 133 covers the right side of the fourth coil 134. Through such an arrangement, the centers of the coils are not stacked but placed side by side with each other, thereby making the coupling coefficient more uniform, reducing the blind spot of the coupling, and increasing the chargeable area (or active area). In one embodiment, the coils are windings made of single-strand or multi-strand enameled stranded wire. In one embodiment, the wire material of the winding preferably includes a self-adhesive wire containing a self-adhesive layer.

[0059] In one embodiment, the circuit board 140 of the wireless charging module 100 includes at least one first electronic component 141 and at least one second electronic component 142, the heat generated by the at least one first electronic component 141 is greater than the heat generated by the at least one second electronic component 142, and the at least one first electronic component is closer to the middle of the circuit board than the at least one second electronic component. For example, the at least one first electronic component 141 can be or include a microprocessor or an inductor (choke). In one embodiment, the at least one first electronic component 141 and the at least one second electronic component 142 can include at least one of an NFC component (Near Field Communication Device), an NTC thermistor (Negative Temperature Coefficient Thermal Resistor), a 5G antenna, a FAKRA connector, or an EMI shielding pattern. The NFC component is a short-range high-frequency wireless communication device. The resistance value of the NTC thermistor decreases as the temperature rises, and can be used for temperature sensing, overcurrent protection, or power stabilization.

[0060] In one embodiment, the second surface of the circuit board 140 is closer to the external environment than the first surface thereof. Therefore, a first electronic component 141 such as a microprocessor or a choke may be disposed on the second surface of the circuit board 140 .

[0061] Figure 4 The table is a comparison of the thermal simulation temperatures of different components of a printed circuit board assembly (PCBA) when wireless charging is performed on an electronic device using a wireless charging module with a fan according to an embodiment of the present invention and a wireless charging module without a fan. Figure 4 As shown, the wireless charging module 100 using the fan 120 to form three airflows according to an embodiment of the present invention can effectively reduce the temperature of various parts of the printed circuit board assembly (PCBA) by nearly 20° C. on average.

[0062] Figure 5 The table is a comparison of the thermal simulation temperatures at different locations on the outside of the wireless charging module when wirelessly charging an electronic device using a wireless charging module with a fan according to an embodiment of the present invention and a wireless charging module without a fan. Figure 5 In the figure, Tx coil refers to the coil assembly 130, Tx coil shield refers to the upper cover 115 of the EMI board, A-Surface refers to the middle of the outer surface of the upper cover 115, Main Case refers to the shell body 116, and Bottom Cover refers to the lower cover 117. Figure 5As shown, the wireless charging module 100 using the fan 120 to form three airflows according to one embodiment of the present invention can effectively reduce the temperature of the coil assembly 130 by nearly 26°C; and can effectively reduce the temperature of the middle of the outer surface of the upper cover 115 by nearly 12°C.

[0063] like Figure 4 and Figure 5 As shown, the wireless charging module 100 includes a first air duct 191 , a second air duct 192 and a third air duct 193 , which can dissipate heat from the components of the wireless charging module 100 more efficiently. The air ducts can form effective spatial convection and effectively dissipate heat.

[0064] In one embodiment, the blades of the fan 120 are made of a polymer or metal, and the fan 120 is regulated by pulse width modulation (PWM) to control the noise generated by the wireless charging module 100 within a specific range. In addition, the speed of the fan 120 may be adjustable or non-adjustable. In one embodiment, Figure 2 As shown, the distance H2 between the middle partition 118 and the circuit board 140 is smaller than the distance H3 between the circuit board 140 and the lower cover 117. In this way, the air volume of the air flow S in the third air duct 193 can be increased.

[0065] Fig. 6A A simulation diagram of the flow field of a wireless charging module according to an embodiment of the present invention is shown. Figure 6B The table shows the air flow in each air duct of the wireless charging module according to an embodiment of the present invention. Fig. 6A and 6B In the embodiment, a small fan 120 with a size of 25mm×25mm×10mm is used as an active heat dissipation solution, and the cooling effect is successfully achieved. In one embodiment, a larger air volume can be generated in the middle of the fan 120, while a smaller air volume is generated on the outer side of the fan 120. Therefore, making the inlet area of ​​the third air duct 193 larger can make the air volume of the airflow S in the second air duct 192 and the third air duct 193 more uniform. Figure 6B As shown in the table, the proportions of the flow rates of the airflow S in the first air duct 191, the second air duct 192 and the third air duct 193 are 25%, 39% and 36% respectively.

[0066] In addition, please refer to Fig. 6A The flow field of the airflow is shown in Figure 1. Fig. 6AFrom the flow field diagram, it can be seen that the flow rate of the airflow S flowing through the center of the first cavity 121 or the second cavity 122 is greater than the flow rate flowing through the corner of the first cavity 121 or the second cavity 122. Therefore, in one embodiment, components with a large heat generation, such as a microprocessor or an inductor, can be arranged near the center of the circuit board 140 or the second cavity 122, rather than at the corner of the circuit board 140 or the second cavity 122.

[0067] According to an embodiment of the present invention, the wireless charging module 100 is provided with a first air duct 191, a second air duct 192 and a third air duct 193, which can form effective spatial convection and can effectively dissipate heat for the wireless charging module 100 with high wattage (e.g., >15W) and fast charging.

Claims

1. A wireless charging module, characterized in that: include: A module housing defines a first cavity and a second cavity, and has a first side and a second side opposite to the first side, wherein the second side defines an air outlet; at least one fan, disposed on the first side of the module housing, for forming an airflow S; a coil assembly, used for generating electromagnetic induction, and disposed in the first cavity, so as to form a first air duct for allowing the airflow S to pass through a first surface of the coil assembly; a circuit board, configured to be located in the second cavity, so as to form a second air duct for the airflow S to pass through the first surface of the circuit board, and to form a third air duct for the airflow S to pass through the second surface of the circuit board, in, The airflow S passes through the first air duct, the second air duct, and the third air duct, and flows out of the wireless charging module from the air outlet.

2. The wireless charging module according to claim 1, characterized in that: The second air duct is located between the first air duct and the third air duct.

3. The wireless charging module according to claim 1, characterized in that: The circuit board includes at least one first electronic component and at least one second electronic component, wherein: The heat generated by the at least one first electronic component is greater than the heat generated by the at least one second electronic component, and the at least one first electronic component is located closer to the middle of the circuit board than the at least one second electronic component.

4. The wireless charging module according to claim 1, characterized in that: The module housing comprises an upper cover, a shell body and a lower cover. The shell body has a middle partition. The first air duct is formed between the middle partition and the upper cover, the second air duct is formed between the middle partition and the circuit board, and the third air duct is formed between the circuit board and the lower cover.

5. The wireless charging module according to claim 4, characterized in that: The distance between the middle partition and the circuit board is smaller than the distance between the circuit board and the lower cover.

6. The wireless charging module according to claim 4, characterized in that: Also includes: A magnetic core element is located below the coil group. The coil group and the magnetic core element are tightly bonded to the middle partition of the module housing.

7. The wireless charging module according to claim 1, characterized in that: The coil set includes: a first coil, a second coil and a third coil. The left side of the first coil covers the right side of the second coil, and the left side of the second coil covers the right side of the third coil.

8. The wireless charging module according to claim 1, characterized in that: The fan blades are made of high molecular weight polymer or metal, and The fan is speed-regulated by pulse width modulation, thereby controlling the noise generated by the wireless charging module to be within a specific range.

9. The wireless charging module according to claim 4, characterized in that: The upper cover is an EMI board. The lower cover is a metal plate. The module housing further has a third side and a fourth side, the third side is opposite to the fourth side, and both the third side and the fourth side extend between the first side and the second side.

10. The wireless charging module according to claim 7, characterized in that: The first coil, the second coil and the third coil are windings made of single-strand or multi-strand enameled twisted wires.

11. The wireless charging module according to claim 10, characterized in that: The wire material of the winding comprises a self-adhesive wire containing a self-adhesive layer.

12. The wireless charging module according to claim 6, characterized in that: The material of the magnetic core element includes manganese-zinc ferrite, nickel-zinc ferrite, ferrite or nanocrystalline magnetic material, and the magnetic core element is made by sintering or ceramic injection molding.

13. The wireless charging module according to claim 1, characterized in that: The module housing is made of metal or plastic and is manufactured by stamping, die-casting, injection molding, or machining.

14. The wireless charging module according to claim 2, characterized in that: The at least one first electronic component and the at least one second electronic component include at least one of an NFC component, an NTC thermistor, a 5G antenna, a FAKRA connector, or an EMI shielding pattern.

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