Wireless Charger Coil Encapsulation for Fast-Charging Heat Control
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Solution Overview
Problem
Wireless charging devices often stop high-wattage fast charging when the device temperature reaches a certain threshold, prolonging charging time to prevent overheating.
Innovation Solution
A wireless charger design with a heat-conducting material encapsulating the transmitting coils, in contact with a metallic case, to manage coil temperature effectively.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If wireless charging is performed at high wattage, then charging speed is improved, but device temperature increases causing charging mode to drop
Solution Approach 1:
A heat-conducting material is introduced as an intermediary substance between the transmitting coils and the metallic case. This material with specific thermal conductivity (0.1-10 W/(m·K)) acts as a thermal mediator that controls heat transfer from the coils to the case, preventing excessive temperature rise while maintaining efficient charging performance
Solution Approach 2:
The patent changes the thermal conductivity parameter of the interface material between coils and case. By selecting materials with specific thermal conductivity values (0.1-10 W/(m·K)), the heat transfer rate is controlled to maintain coil temperature below 34.2°C, resolving the contradiction between fast charging and temperature control
2Reliability
If device temperature is controlled below threshold, then thermal safety is improved, but charging time increases due to load reduction
Solution Approach 1:
The heat-conducting material is pre-installed between the coils and metallic case before operation. This preliminary thermal management structure ensures that heat is continuously conducted away from the coils during charging, allowing the system to maintain high-wattage fast charging mode without triggering temperature-based load reduction
Solution Approach 2:
The patent converts the potentially harmful heat generated during fast charging into a manageable thermal flow by using the heat-conducting material to channel heat to the metallic case. This transforms the harmful thermal effect into a controlled heat transfer process that maintains safety while preserving charging speed
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
Maintains coil temperature below 34.2°C, compared to conventional chargers' 40°C, ensuring efficient and faster charging without thermal cutoffs.
Implementation Method 1
a first heat-conducting material is disposed on a top surface of the at least one coil to encapsulate the at least one coil, wherein the first heat-conducting material fills into a space between a sidewall of the first recess and the at least one coil with the heat-conducting material being in contact with said sidewall and a bottom surface of the first recess
Data Source
AI summary
A wireless charger having coils disposed in a recess of a metallic case of the wireless charger, wherein a heat-conducting material is disposed in the recess to encapsulate the coils with the first heat-conducting material being in contact with the coils, a sidewall, and a bottom surface of the recess.