Overlapping Secondary Coil Layout for Misaligned Wireless Charging
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Solution Overview
Problem
Conventional wireless power systems face inefficiencies due to misalignment of primary and secondary coils, leading to reduced charging capability and increased electromagnetic interference, especially when a single secondary coil is not well-aligned with the primary coil.
Innovation Solution
The implementation of a wireless power reception apparatus with multiple secondary coils, including a main secondary coil and auxiliary secondary coils, where portions of the coils are stacked and placed within voids in a ferrite material to maintain a consistent thickness and ensure efficient power transfer even during misalignment, along with a printed circuit board configuration that includes conductive material layers for enhanced power reception.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a single secondary coil is used in the wireless power reception apparatus, then the device complexity is reduced, but the charging efficiency deteriorates when misalignment occurs between primary and secondary coils
Solution Approach 1:
The single secondary coil is segmented into multiple secondary coils (first secondary coil, second secondary coil, third secondary coil) arranged in different spatial positions. Each coil can independently or collectively receive power from the primary coil, ensuring that at least one coil maintains effective coupling even when misalignment occurs, thereby resolving the contradiction between device simplicity and charging efficiency under misalignment conditions
2Productivity
If multiple secondary coils are added to ensure power delivery during misalignment, then the charging efficiency is improved, but the device complexity increases
Solution Approach 1:
Multiple secondary coils are merged into a unified power reception system where their individual outputs are combined to deliver total power to the load. The controller integrates power from multiple coils simultaneously, achieving robust power delivery during misalignment while managing complexity through systematic integration rather than independent coil operations
3Length of stationary object
If a ferrite layer with void is introduced to accommodate stacked coils, then the thickness consistency is improved, but the manufacturing complexity increases
Solution Approach 1:
The ferrite layer is designed with non-uniform structure, incorporating voids at specific locations where stacked secondary coils need to be accommodated. This local modification allows the ferrite material to maintain its magnetic shielding properties in most areas while providing necessary space for coil stacking, achieving thickness consistency without requiring complete redesign of the entire ferrite layer
4Reliability
If overlapping coil configurations are used to maintain power transfer during misalignment, then the reliability is improved, but the electromagnetic interference increases
Solution Approach 1:
The ferrite layer acts as an intermediary material between the overlapping secondary coils and the external environment. It provides magnetic shielding that contains and directs the magnetic flux generated by the coils, reducing electromagnetic interference radiating outward while maintaining effective magnetic coupling between the primary and secondary coils for reliable power transfer
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
This configuration ensures consistent voltage delivery to a load, maintaining charging efficiency and reducing electromagnetic interference by distributing power contributions across multiple coils, even when the primary and main secondary coils are misaligned, thus enhancing the overall efficiency of wireless charging systems.
Implementation Method 1
a primary coil that produces an electromagnetic field. The electromagnetic field may induce a voltage in a secondary coil of a wireless power reception apparatus when the secondary coil is placed in proximity to the primary coil
Implementation Method 2
a ferrite layer having a void. The wireless power reception apparatus may also include a first secondary coil configured to generate first power in cooperation with one or more primary coils
Data Source
AI summary
One innovative aspect of the subject matter described in this disclosure can be implemented in a wireless power reception apparatus. In some implementations, the wireless power reception apparatus may include a ferrite layer including a void. The wireless power reception apparatus may also include a first secondary coil configured to generate first power in cooperation with one or more primary coils of a wireless power transmission apparatus, where at least a portion of the first secondary coil resides in the void of the ferrite layer. The wireless power reception apparatus may also include one or more second secondary coils configured to generate second power in cooperation with the one or more primary coils of the wireless power transmission apparatus, where a portion of the second secondary coil is overlaying the portion of the first secondary coil residing in the void of the ferrite layer.