Multi-layer Shim Assembly for Wireless Power Coil Alignment
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Solution Overview
Problem
Constructing primary coil arrays for wireless power supplies is challenging due to complex connection management, alignment issues, and efficiency losses, particularly at higher power levels and in high-volume production, with existing solutions like printed circuit boards facing inefficiencies and heat management problems.
Innovation Solution
A multi-layer shim assembly is introduced, using non-conductive shims with alignment guides and wire routing channels to facilitate the construction of multi-layer coil arrays, allowing for efficient alignment and connection of coils and wires, reducing the thickness of the wireless power supply and improving power transfer efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If multiple primary coils are configured in an array to increase power transfer surface and capability, then the power transfer capability and surface area are improved, but the complexity of managing connections and aligning coils increases significantly
Solution Approach 1:
Multiple separate connection management functions (alignment, routing, securing) are merged into a single integrated shim assembly that provides all these functions simultaneously, reducing overall system complexity while maintaining multi-coil array capabilities
Solution Approach 2:
The shim assembly serves multiple functions simultaneously: it provides alignment guides for coil positioning, channels for wire routing, and structural support for securing coils, thereby managing connection complexity through a multi-functional component
2Reliability
If individual connections are made between each coil and wireless power circuitry, then proper electrical connections are established, but the construction time and labor intensity increase
Solution Approach 1:
The shim assembly is prepared in advance with pre-formed alignment guides and routing channels, allowing coils and wires to be quickly installed without time-consuming manual alignment and routing during assembly
Solution Approach 2:
The shim assembly acts as an intermediary component between the coils and the wireless power circuitry, providing a structured interface that simplifies connection establishment while ensuring proper electrical connections
3Loss of energy
If primary coils are secured in precise positions to maintain electromagnetic field efficiency, then power transfer efficiency is improved, but the alignment process becomes tedious and time-consuming
Solution Approach 1:
The alignment guides on the shim assembly enable the coils to be self-aligned during installation, eliminating the need for time-consuming manual alignment processes while ensuring precise positioning for optimal electromagnetic field efficiency
Solution Approach 2:
Manual mechanical alignment is replaced by fixed geometric alignment guides on the shim assembly, which automatically ensure correct coil positioning without requiring tedious manual adjustment
4Reliability
If wires are routed over coils to reach wireless power circuitry, then connections are established, but the stack thickness increases and electromagnetic field generation is negatively impacted
Solution Approach 1:
The routing function is segmented from the coil array structure, with dedicated routing channels provided by the shim assembly that separate wire routing paths from the electromagnetic field generation area, preventing wires from crossing over coils
Solution Approach 2:
Wire routing is moved from a vertical path over the coils to a horizontal path through dedicated channels in the shim assembly, changing the routing dimension and avoiding interference with the electromagnetic field while maintaining connection reliability
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The multi-layer shim assembly simplifies the construction process, enhances alignment and wire routing, and reduces efficiency losses, enabling more efficient and reliable high-power wireless power transfer while minimizing thickness and heat issues.
Implementation Method 1
Power is supplied from a wall outlet, the circuitry uses the power to energize the primary coil producing an electromagnetic field
Implementation Method 2
When the remote device is placed in proximity of the electromagnetic field generated by the primary coil, the secondary coil receives the energy
Data Source
AI summary
A wireless power supply includes a multi-layer shim assembly. Each shim aids in alignment of coils and routing of conductors in a multi-layer coil array. A shield or PCB can be used as part of the multi-layer shim assembly. Wires can be routed through channels to the edge of the shim assembly or wires can protrude through a portion of the multi-layer shim assembly. Traces can be used to route current through the multi-layer shim assembly. Plastic shims can be created by over-molding coils with plastic.