Integrated Wireless Charger Layout for USB-PD Heat Control
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Solution Overview
Problem
Existing wireless charging devices for vehicles are inefficient in terms of cost and space usage due to separate components for wireless charging and USB-PD functions, and they face challenges in managing heat and output when both functions are used simultaneously.
Innovation Solution
A wireless charging device with integrated USB-PD function, featuring a rectangular shield assembly with a first coil for magnetic induction coupling, a main PCB with an inverter for power conversion, and a sub-PCB with a USB Type-C port, which allows for simultaneous wireless charging and USB-PD charging while monitoring and controlling output power to manage heat and efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If wireless charging device and USB-PD board are disposed in different areas as separate parts, then each component can be independently manufactured and assembled, but manufacturing costs increase and vehicle space usage becomes inefficient
Solution Approach 1:
The patent combines the wireless charging device and USB-PD board into a single integrated unit. The USB-PD board is mounted on the same substrate as the wireless charging coil, and the controller integrates both wireless charging control and USB-PD power delivery control functions. This merging eliminates the need for separate manufacturing and assembly of distinct components, reducing overall system complexity while maintaining manufacturing feasibility.
Solution Approach 2:
The integrated device performs multiple functions simultaneously - it provides both wireless charging capability and USB-PD power delivery through a single unified system. The controller can manage both wireless power transmission and wired USB-PD charging, allowing the same physical space and power supply infrastructure to serve dual purposes, thereby improving space efficiency and reducing component count.
2Productivity
If wireless charging and USB-PD charging are performed simultaneously, then users can charge multiple devices at once, but heat management becomes more difficult and output control complexity increases
Solution Approach 1:
The controller continuously monitors the charging state of both wireless and USB-PD channels, detecting when both are operating simultaneously. Based on this feedback, the controller dynamically adjusts power distribution and implements heat management strategies. The system can prioritize power allocation, adjust charging rates, or activate cooling mechanisms when thermal thresholds are approached, enabling safe simultaneous operation of both charging functions.
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 integration reduces manufacturing costs, optimizes space usage, and enables stable and efficient power delivery by dynamically adjusting USB-PD profiles based on charging conditions, effectively managing heat and output during simultaneous operations.
Implementation Method 1
a first coil for delivering power to a terminal including a second coil by magnetic induction coupling
Data Source
AI summary
The wireless charging device according to an embodiment may comprise a rectangular shield assembly in which a shield and a first coil for delivering power to a terminal including a second coil by magnetic induction coupling are formed, a main PCB including an inverter that converts DC power into AC power and supplies it to the first coil, and a sub-PCB attached to one corner of the shield assembly and including a USB Type-C port. The sub-PCB may be disposed outside the first coil. The USB Type-C port may be exposed in a direction perpendicular to a plane on which the terminal is placed.