Surface-Mount Wireless Power Transmitter for Thick-Surface Charging
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Solution Overview
Problem
Existing wireless power transmitters are limited to operating at small separation gaps of 3-5 mm, making them ineffective for transmitting power through thicker materials like cabinets and countertops, which restricts modularity and requires expensive built-in chargers.
Innovation Solution
A surface mountable wireless power transmitter with a ferrite core that surrounds the transmitter antenna on three sides, allowing for power transfer at extended separation gaps of up to 15 mm or more, while maintaining efficient thermal mitigation and modularity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If a wireless power transmitter is designed to operate at small separation gaps (3-5 mm) for efficient power transfer, then power transfer efficiency is improved, but the transmitter cannot transmit through thicker materials like cabinets and countertops, requiring expensive built-in chargers and limiting modularity
Solution Approach 1:
The patent changes the operating frequency parameter from the conventional 6.78 MHz (Qi standard) to a lower frequency range (87-205 kHz). This parameter change enables the transmitter to achieve both extended separation gaps (15-30 mm) and maintain power transfer efficiency, while also providing thermal mitigation capabilities for use with thicker materials without requiring built-in installation
Solution Approach 2:
The patent introduces a ferrite core as an intermediary component that concentrates and directs the magnetic field between the transmitter and receiver coils. This ferrite mediator enhances magnetic coupling efficiency at extended separation distances and provides thermal management, enabling the system to work through thicker materials while maintaining efficiency and avoiding the need for expensive built-in chargers
2Adaptability or versatility
If the separation gap is increased to transmit through thicker materials, then adaptability and modularity are improved, but power transfer efficiency decreases and thermal management becomes more difficult
Solution Approach 1:
By operating at lower frequencies (87-205 kHz) rather than the standard 6.78 MHz, the transmitter achieves extended separation gaps of 15-30 mm while maintaining power transfer efficiency. This frequency parameter change fundamentally alters the electromagnetic field characteristics to enable both long-range operation and efficient power transfer simultaneously
Solution Approach 2:
The ferrite core provides localized magnetic field concentration and directionality between the coils. This local enhancement of magnetic coupling at the critical interface between transmitter and receiver maintains high power transfer efficiency even when the overall separation gap is increased to 15-30 mm, enabling modularity without efficiency loss
3Adaptability or versatility
If the separation gap is increased to 15 mm or greater, then compatibility with thicker materials is improved, but thermal mitigation becomes more challenging to prevent damage to transmitter, receiver, or surface
Solution Approach 1:
The lower operating frequency (87-205 kHz) inherently produces less electromagnetic heating compared to higher frequencies. Combined with the ferrite core's magnetic field concentration, this parameter change enables extended separation gaps while actively mitigating thermal effects, preventing damage to the transmitter, receiver, or surface materials
Solution Approach 2:
The ferrite core acts as a thermal barrier and magnetic field concentrator, directing magnetic flux efficiently between coils while preventing excessive heat generation and propagation. This intermediary protection enables safe operation at 15-30 mm separation gaps through thick materials without risking thermal damage to components or surfaces
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
Enables wireless power transfer over larger separation gaps without damaging the transmitter, receiver, or surface, providing greater modularity and compatibility with thicker materials, thus overcoming the limitations of legacy transmitters.
Implementation Method 1
a shielding comprising a ferrite core and defining a cavity, the cavity configured such that the ferrite core substantially surrounds all but the top face of the coil
Implementation Method 2
inductive wireless power transfer, which occurs when magnetic fields created by a transmitting element induce an electric field, and hence, an electric current, in a receiving element
Implementation Method 3
The surface mountable housing further includes a heat sink, the heat sink configured to rest, at least in part, below the transmitter antenna, when the power transmitter is connected to the structural surface, and configured to direct heat generated by the power transmitter away from the structural surface
Data Source
AI summary
A surface mountable housing for a power transmitter for wireless power transfer includes a connector system configured for use to mount, at least, a transmitter antenna to an underside of a structural surface, such that the transmitter antenna is configured to couple with a receiver antenna of a power receiver when the receiver antenna is proximate to a top side of the structural surface. The surface mountable housing further includes a heat sink, the heat sink configured to rest, at least in part, below the transmitter antenna, when the power transmitter is connected to the structural surface, and configured to direct heat generated by the power transmitter away from the structural surface, and an antenna housing, the antenna housing substantially surrounding a side wall of the transmitter antenna, the antenna housing connected to the heat sink and positioned between the heat sink and the structural surface.