Wireless Charging Module

Abstract

To provide a wireless charging module in which an effective spatial convection is formed by air channels and heat can be effectively dissipated, for charging an electronic device.SOLUTION: A wireless charging module 100 includes a module case 110, a fan 120, a coil assembly 130 and a circuit board 140. The module case defines first and second cavities 121 and 122 and has a first side 111 and a second side 112 opposite to the first side. The fan is disposed at the first side of the module case and configured to form an airflow, and an air outlet 119 is formed in the second side. The coil assembly is disposed in the first cavity, so that a first air channel is formed for the airflow to pass through a surface of the coil assembly at the side of an upper cover 115. The circuit board is disposed in the second cavity and configured to form a second air channel 192 allowing the airflow to pass through a first surface of the circuit board and a third air channel allowing the airflow to pass through a second surface of the circuit board.SELECTED DRAWING: Figure 1

Description

[Technical field]

[0001] The present invention relates to a charging module for charging an electronic device, and more particularly to a wireless charging module for charging an electronic device. [Background technology]

[0002] As consumer products that support wireless charging become more and more popular, the demand for wireless charging modules that support high wattage (e.g., 15W or more) fast charging in automotive products is also increasing. Therefore, there is a strong demand in the market for an increased active area and heat dissipation effect during high wattage charging. Summary of the Invention [Problem to be solved by the invention]

[0003] Typically, operating temperature is the main important factor affecting the service life of electronic components. Thermal simulation diagrams of existing wireless charging modules show that heat may be concentrated in certain hotspot areas, adversely affecting the service life of electronic components and leading to reduced charging power. For example, coils, magnetic cores (ferrites), electronic components, etc. may generate high heat due to losses, which may affect the reliability and service life of components. [Means for solving the problem]

[0004] According to one embodiment of the present invention, there is provided a wireless charging module for charging an electronic device. According to another embodiment of the present invention, there is provided a wireless charging module including a first airway, a second airway, and a third airway for charging an electronic component and dissipating heat from the components of the wireless charging module. According to an embodiment of the present invention, there is provided a wireless charging module including a module case, at least one fan, a coil assembly, and a circuit board. The module case defines a first cavity and a second cavity, has a first side and a second side opposite to the first side, and the second side defines an air outlet. At least one fan is installed on the first side of the module case to form an airflow S. A coil assembly is installed in the first cavity to generate electromagnetic induction and form a first airway that allows the airflow S to pass through a first surface of the coil assembly. A circuit board is installed in the second cavity, thereby forming a second airway that allows the airflow S to pass through a first surface of the circuit board, and thereby forming a third airway that allows the airflow S to pass through a second surface of the circuit board. The airflow S passes through the first air passage, the second air passage, and the third air passage, and flows out from the air outlet to the outside of the wireless charging module.

[0005] In one embodiment, the second air duct is located between the first air duct and the third air duct.

[0006] In one embodiment, the circuit board includes at least one first electronic component and at least one second electronic component, the heat generation amount of the at least one first electronic component being greater than the heat generation amount of the at least one second electronic component, and the at least one first electronic component being located closer to a center of the circuit board than the at least one second electronic component.

[0007] In one embodiment, the module case includes an upper cover, a case body, and a lower cover. The case body has a middle partition. The first air passage is formed between the middle partition and the upper cover, the second air passage is formed between the middle partition and the circuit board, and the third air passage is formed between the circuit board and the lower cover.

[0008] In one embodiment, the distance between the intermediate partition and the circuit board is less than the distance between the circuit board and the bottom cover.

[0009] In one embodiment, the wireless charging module further includes a magnetic core member (Ferrite), which is located below the coil assembly, and the coil assembly and the magnetic core member are tightly attached to the middle partition of the module case.

[0010] 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, the first coil, the second coil, and the third coil are preferably windings made of single or multiple enameled wires.

[0011] In one embodiment, the material of the fan blades is polymer or metal, and the speed of the fan is adjusted by pulse-width modulation (PWM) to control the noise generated by the wireless charging module within a specific range.

[0012] In one embodiment, the upper cover is an EMI board and the lower cover is a metal plate. The module case has a third side and a fourth side, the third side faces the fourth side, and the third side and the fourth side both extend between the first side and the second side.

[0013] In one embodiment, the winding wire includes a self-adhesive wire including a self-adhesive layer. In one embodiment, the material of the magnetic core preferably 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 is manufactured by sintering or ceramic injection molding.

[0014] In one embodiment, the module case is made of a metal or plastic material and is manufactured by pressing, die-casting, injection molding, or processing using a processing machine. In one embodiment, the at least one first electronic component and the at least one second electronic component preferably include at least one of an NFC component, an NTC thermistor, a 5G antenna, a FAKRA connector, or an EMI shielding pattern.

[0015] According to one embodiment of the present invention, the wireless charging module includes a first air passage, a second air passage and a third air passage, so that the components of the wireless charging module can dissipate heat more efficiently, and these air passages can form effective spatial convection, thereby enabling effective heat dissipation. [Brief description of the drawings]

[0016] [Figure 1] FIG. 2 is an exploded view of a wireless charging module according to one embodiment of the present invention. [Diagram 2] FIG. 2 is a perspective view of a wireless charging module according to one embodiment of the present invention. [Diagram 3] FIG. 2 is a cross-sectional perspective side view of a wireless charging module according to one embodiment of the present invention. [Figure 4] 1 is a table comparing thermal simulation temperatures of different components when an electronic device is wirelessly charged using a wireless charging module with a fan and a wireless charging module without a fan according to an embodiment of the present invention; [Diagram 5]1 is a table comparing thermal simulation temperatures at different positions on the outside of a wireless charging module when an electronic device is wirelessly charged using a wireless charging module with a fan and a wireless charging module without a fan according to an embodiment of the present invention. [Figure 6A] 1 shows a flow field simulation diagram of a wireless charging module according to an embodiment of the present invention. [Figure 6B] 13 illustrates a table of airflow in each air duct of a wireless charging module in accordance with an embodiment of the present invention. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0017] FIG 1 shows an exploded view of a wireless charging module according to an embodiment of the present invention. FIG 2 shows a perspective view of a wireless charging module according to an embodiment of the present invention. FIG 3 shows a cross-sectional perspective side view of a wireless charging module according to an embodiment of the present invention.

[0018] According to an embodiment of the present invention, as shown in FIGS. 1 to 3, the wireless charging module 100 includes a module case 110, at least one fan 120, a coil assembly 130, and a circuit board 140. The module case 110 defines a first cavity 121 and a second cavity 122, and has a first side 111 and a second side 112 opposite to the first side 111, and the second side 112 defines an air outlet 119. In this embodiment, an example in which the number of fans 120 is one will be described. The fan 120 is installed on the first side 111 of the module case 110 to form an airflow S. The circuit board 140 may be a printed circuit board assembly (PCBA). The printed circuit board assembly includes main electronic components of the wireless charging module 100, and heat generated by the electronic components is mainly dissipated to the outside of the wireless charging module 100 through thermal convection.

[0019] The coil assembly 130 is used to generate electromagnetic induction and is installed in the first cavity 121 to form a first airway 191 through which the airflow S passes over a first surface of the coil assembly 130. A second surface of the coil assembly 130 faces the module case 110 and defines the surface of the first cavity 121. As shown in FIG. 2 to FIG. 3, the circuit board 140 is configured to be installed in the second cavity 122 to form a second airway 192 through which the airflow S passes over the first surface of the circuit board 140, and a third airway 193 through which the airflow S passes over the second surface of the circuit board 140 is formed. The airflow S passes through the first airway 191, the second airway 192, and the third airway 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 in the embodiment of FIG. 2, the first surface of the circuit board 140 is the upper surface, and the second surface of the circuit board 140 is the lower surface.

[0020] In one embodiment, as shown in FIG. 1, the module case 110 includes an upper cover 115, a case body 116, and a lower cover 117. The case body 116 has a middle partition 118, a first airway 191 is formed between the middle partition 118 and the upper cover 115, a second airway 192 is formed between the middle partition 118 and the circuit board 140, and a third airway 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 case 110. In one embodiment, the material of the module case 110 may be a metal or plastic material, and in one embodiment, the module case 110 may be manufactured by pressing, die casting, injection molding, or processing using a processing machine.

[0021] 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 (the upper surface in the embodiment of FIG. 1). In one embodiment, the wireless charging module 100 further includes a magnetic core member (ferrite) 132. The magnetic core member 132 is located under the coil assembly 130. The coil assembly 130 and the magnetic core member 132 are adhered as tightly as possible to the middle partition 118 of the module case 110. In one embodiment, the material of the magnetic core member 132 includes manganese zinc ferrite, nickel zinc ferrite, ferrite or nanocrystalline magnetic material, and the magnetic core member 132 is fabricated by sintering or ceramic injection molding.

[0022] In one embodiment, the upper cover 115 may be an EMI board (Electromagnetic interference board). An EMI board is a circuit board used to reduce electromagnetic interference (EMI) generated by electronic devices and resist external EMI interference. The lower cover 117 is a metal plate for improving heat dissipation effect. The module case 110 further has a third side 113 and a fourth side 114. The third side 113 faces the fourth side 114, and both the third side 113 and the fourth side 114 extend between the first side 111 and the second side. In one embodiment, neither the third side 113 nor the fourth side 114 defines a through hole. The fan 120 is installed on the first side 111 of the module case 110, and an air outlet 119 is defined on the second side 112, so that the airflow S flows in from the first side 111 and then flows out from the air outlet 119 of the second side 112, forming an airflow field that dissipates heat.

[0023] In one embodiment, the coil assembly 130 includes a first coil 131, a second coil 132, and a third coil 133. As seen from FIG. 1, 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 further includes a fourth coil 134, and the left side of the third coil 133 covers the right side of the fourth coil 134. With this arrangement, the centers of the coils are not stacked but are arranged side by side, so that the coupling coefficient becomes more uniform, the dead angle of the coupling is reduced, and the chargeable area (also referred to as the active area) is increased. In one embodiment, the coils are windings made of single or multiple enameled wires or enameled twisted wires. In one embodiment, the wires of the windings preferably include fused wires including a self-bonding layer.

[0024] In one embodiment, the circuit board 140 of the wireless charging module 100 includes at least one first electronic member 141 and at least one second electronic member 142. The heat value of the at least one first electronic member 141 is greater than that of the at least one second electronic member 142. The position of the at least one first electronic member on the circuit board is closer to the center than the at least one second electronic member. For example, the at least one first electronic member 141 may be or include a microprocessor or an inductor. In one embodiment, the at least one first electronic member 141 and the at least one second electronic member 142 may include at least one of an NFC member (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 member is a near-field high-frequency wireless communication device. The resistance of an NTC thermistor decreases as the temperature rises, and it is used for temperature detection, overcurrent protection, and power supply stabilization.

[0025] In one embodiment, the second surface of the circuit board 140 is closer to the external environment than the first surface, so that a first electronic component 141, such as a microprocessor and an inductor (choke), can be placed on the second surface of the circuit board 140.

[0026] 4 is a comparison of thermal simulation temperatures of different components of a printed circuit board assembly (PCBA) when an electronic device is wirelessly charged using a wireless charging module with a fan and a wireless charging module without a fan according to an embodiment of the present invention. As shown in FIG. 4, the wireless charging module 100 using a fan 120 to form three airflows according to an embodiment of the present invention can reduce the temperature of various components of the printed circuit board assembly (PCBA) by approximately 20° C. on average.

[0027] FIG. 5 is a comparison of thermal simulation temperatures at different positions on the outside of a wireless charging module when an electronic device is wirelessly charged using a wireless charging module with a fan and a wireless charging module without a fan according to an embodiment of the present invention. In FIG. 5, Tx coil refers to the coil assembly 130, and Tx coil shield refers to the top cover 115 of the EMI board. A-Surface refers to the center of the outer surface of the top cover 115. Main Case refers to the case body 116, and Bottom Cover refers to the bottom cover 117. As shown in FIG. 5, 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 the coil assembly 130 by nearly 26°C, and can effectively reduce the temperature of the center of the outer surface of the top cover 115 by nearly 12°C.

[0028] 4 and 5, the wireless charging module 100 includes a first air duct 191, a second air duct 192, and a third air duct 193 that can more efficiently dissipate heat from components of the wireless charging module 100. These air ducts form effective spatial convection and can effectively dissipate heat.

[0029] In one embodiment, the material of the blade of the fan 120 is a polymer or metal, and the speed of the fan 120 is adjusted by pulse-width modulation (PWM) to control the noise caused by the wireless charging module 100 within a certain range. Moreover, the rotation speed of the fan 120 may be adjustable or non-adjustable. In one embodiment, as shown in FIG. 2, 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. This can increase the volume of the airflow S in the third air passage 193.

[0030] FIG. 6A shows a simulation diagram of the flow field of the wireless charging module according to an embodiment of the present invention. FIG. 6B shows a table of the air flow rate in each airway of the wireless charging module according to an embodiment of the present invention. Since the wireless charging module 100 usually has a size limit, in the embodiment of FIG. 6A and FIG. 6B, a small fan 120 having a size of 25 mm×25 mm×10 mm is used as an active heat dissipation measure to achieve the cooling effect. In one embodiment, the central part of the fan 120 can generate a larger air volume, and the outer part of the fan 120 can generate a smaller air volume. Therefore, by increasing the inlet area of ​​the third airway 193, the air volume of the airflow S in the second airway 192 and the third airway 193 can be made more uniform. As shown in the table of FIG. 6B, the flow rate ratios of the airflow S in the first airway 191, the second airway 192, and the third airway 193 are 25%, 39%, and 36%, respectively.

[0031] 6A, it can be seen from the flow field diagram of FIG. 6A 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 of the airflow S flowing through the corners of the first cavity 121 or the second cavity 122. Thus, in one embodiment, components that generate a large amount of heat, such as a microprocessor or an inductor, can be placed in the center of the circuit board 140 or the second cavity 122, rather than in the corners of the circuit board 140 or the second cavity 122.

[0032] 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. These air ducts can form effective spatial convection and can effectively dissipate heat from the high wattage (e.g., 15W or more) fast charging wireless charging module 100. [Explanation of symbols]

[0033] 100: Wireless charging module 110: Module case 111: First side 112: Second side 113: Third side 114: Fourth side 115: Top cover 116: Case body 117: Lower cover 118: Intermediate partition 119: Wind outlet 120: Fan 121: First cavity 122: Second cavity 130: Coil assembly 131: First coil 132: Second coil 133: Third coil 134: 4th coil 135: Magnetic core member 140: Circuit board 141: First electronic component 142: Secondary electronic components 191: The first wind path 192: The second wind 193: The Third Wind

Claims

1. a module case defining a first cavity and a second cavity, having a first side and a second side opposite the first side, the second side defining an air outlet; At least one fan provided on the first side of the module case to generate an airflow S; a coil assembly used to generate electromagnetic induction and installed in the first cavity, the coil assembly being arranged to form a first air passage that allows the airflow S to pass through a first surface of the coil assembly; a circuit board installed in the second cavity, the circuit board forming a second air passage for passing the airflow S to a first surface of the circuit board and forming a third air passage for passing the airflow S to a second surface of the circuit board; A wireless charging module comprising: The airflow S passes through the first air passage, the second air passage, and the third air passage, and flows out of the wireless charging module through the air outlet. A wireless charging module that features:

2. The wireless charging module according to claim 1 , wherein the second air passage is located between the first air passage and the third air passage.

3. the circuit board includes at least one first electronic component and at least one second electronic component; 2. The wireless charging module of claim 1, wherein the heat generation amount of the at least one first electronic component is greater than the heat generation amount of the at least one second electronic component, and the at least one first electronic component is located closer to the center of the circuit board than the at least one second electronic component.

4. The module case includes an upper cover, a case body, and a lower cover, The case body has an intermediate partition, 2. The wireless charging module of claim 1, wherein the first air passage is formed between the intermediate partition and the upper cover, the second air passage is formed between the intermediate partition and the circuit board, and the third air passage is formed between the circuit board and the lower cover.

5. The wireless charging module according to claim 4 , wherein a distance between the intermediate partition and the circuit board is smaller than a distance between the circuit board and the lower cover.

6. 5. The wireless charging module of claim 4, further comprising a magnetic core member located below the coil assembly, the coil assembly and the magnetic core member being tightly adhered to the middle partition of the module case.

7. the coil assembly includes a first coil, a second coil, and a third coil; 2. The wireless charging module of claim 1 , wherein a left side of the first coil covers a right side of the second coil, and a left side of the second coil covers a right side of the third coil.

8. The material of the fan blade is a polymer or a metal; 2. The wireless charging module of claim 1, wherein the speed of the fan is adjusted by pulse width modulation to control the noise generated by the wireless charging module within a specific range.

9. the top cover being an EMI board; the lower cover is a metal plate; 5. The wireless charging module of claim 4, wherein the module case has a third side and a fourth side, the third side facing the fourth side, and both the third side and the fourth side extending between the first side and the second side.

10. 8. The wireless charging module according to claim 7, wherein the first coil, the second coil, and the third coil are windings made of a single or multiple enameled wires.

11. The wireless charging module according to claim 10 , wherein the winding wire comprises a fusion wire including a self-fusion layer.

12. 7. The wireless charging module of claim 6, wherein the material of the magnetic core member includes manganese zinc ferrite, nickel zinc ferrite, ferrite or nanocrystalline magnetic material, and the magnetic core member is manufactured by sintering or ceramic injection molding.

13. 2. The wireless charging module according to claim 1, wherein the module case is made of a material selected from the group consisting of metal and plastic, and is manufactured by pressing, die-casting, injection molding, or processing using a processing machine.

14. 3. The wireless charging module of claim 2, wherein 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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