Wireless Charging Coil Array for Longer Range With Lower Heat
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Solution Overview
Problem
Existing wireless power transfer systems face challenges in efficiently transferring power over extended distances and larger volumes while minimizing electromagnetic interference, heat generation, and maintaining system reliability, particularly in harsh environments and multi-bay configurations.
Innovation Solution
The system incorporates components and assemblies that enhance magnetic field concentration, heat dissipation, and electromagnetic interference mitigation, using magnetic materials, multi-layer coils, and firmware settings to optimize power transfer at extended distances and volumes, while incorporating rugged design features to withstand shocks and vibrations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of stationary object
If transmitter inductance and/or receiver inductance are increased to counteract coupling decrease at larger distances, then wireless power transfer capability at extended distances is improved, but equivalent series resistance increases leading to more heat and greater energy losses
Solution Approach 1:
The patent divides the wireless power transfer system into multiple independent transmitting elements arranged in an array. Each element operates at its optimal inductance level, avoiding the need to increase inductance of single elements to extend charging distance. The collective array provides extended range while maintaining efficient energy transfer at the element level.
Solution Approach 2:
The patent transitions from single-element inductive coupling to a multi-element array configuration, adding spatial dimensionality to the system. This array architecture enables extended wireless charging distance through constructive interference and coordinated operation of multiple elements, rather than relying on increased inductance of individual components.
2Length of stationary object
If transmitter inductance and/or receiver inductance are increased to achieve longer-distance power transfer, then coupling at extended distances is improved, but heat generation increases
Solution Approach 1:
By segmenting the transmitting function across multiple elements, each operating at optimal inductance, the system achieves extended range without the heat penalties associated with high-inductance single-element designs. The distributed architecture allows efficient power transfer at lower temperatures.
Solution Approach 2:
The patent converts what would be a limitation (the need for high inductance to extend range) into an advantage by using multiple low-inductance elements. This approach inadvertently benefits from reduced resistive heating while achieving the desired extended charging distance through array coordination.
3Device complexity
If single-transmitter systems are used to simplify system design, then device complexity is reduced, but charging efficacy requires precise alignment which limits adaptability
Solution Approach 1:
The patent segments the transmitting function into multiple independent elements that can operate autonomously or in coordination. This modular approach maintains relatively simple individual component design while providing enhanced adaptability through the collective array, allowing charging of multiple devices with varying positions and orientations.
Solution Approach 2:
The transmitting array is designed to serve multiple functions: it can charge single or multiple devices simultaneously, accommodate various device sizes and positions, and adapt to different charging scenarios. This multi-functionality is achieved while keeping individual element design relatively simple.
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 system enables efficient power transfer over distances of up to 25 mm with reduced EMI and heat buildup, supporting multiple devices and environments with elevated temperatures, and reducing system complexity and cost.
Implementation Method 1
Inductive wireless power transfer occurs when magnetic fields created by a transmitting element induce an electric field, and hence electric current, in a receiving element
Implementation Method 2
a magnetic material, the magnetic material reshaping a magnetic field generated by a wireless power transmitter so that the magnetic field is more concentrated at a distant position
Data Source
AI summary
The present application relates to an apparatus which comprises a wireless power transfer system. This system comprises features which allow it to transfer more power wirelessly at extended distances than other systems operating in the same frequency range. The system possesses heat dissipation features; these features allow it to operate effectively in elevated-temperature environments, and to transfer power at higher levels and/or greater distances than a typical power-transfer system. The system also might include design features to withstand mechanical shocks, stresses, and impacts for use in a rugged environment. The system can also comprise adaptations to reduce electromagnetic interference, and can comprise specially shaped components with magnetic/ferrimagnetic properties that enhance performance. Other potential features include power conditioning by combining, within one circuit or one board, multiple elements that protect against excessive current, over-voltage, and/or reverse voltage.