Wireless Charging Coil With Nanocrystalline Foil for Ferrite Saturation
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Solution Overview
Problem
Conventional wireless charging systems face inefficiencies due to ferrite saturation, heat generation, and interference from external metal or magnetic materials, especially in devices with reduced form factors and those containing hard magnets, which affect charging performance and regulatory compliance.
Innovation Solution
The use of nanocrystalline foil with ferrosilicon-containing materials, characterized by high permeability and flux density saturation, replaces ferrite in wireless charging systems, allowing for improved flux conduction and reduced material thickness, thereby enhancing charging efficiency and accommodating larger coils in compact devices.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If ferrite is used in wireless charging systems, then magnetic flux conduction is achieved, but flux density saturation occurs reducing charging efficiency
Solution Approach 1:
The patent changes the material parameters by replacing ferrite with nanocrystalline material that has superior magnetic properties including higher saturation flux density (Bs > 1.0 T) and higher permeability (μ > 10,000). This parameter change allows the material to handle higher magnetic flux without saturation, directly improving charging efficiency and preventing the saturation problem associated with conventional ferrite materials.
Solution Approach 2:
The patent employs nanocrystalline material as a composite alternative to conventional ferrite. This nanocrystalline material comprises fine-grained crystalline structures with specific compositional ratios (e.g., Fe-Si-B-Nb alloys) that provide enhanced magnetic properties. The composite nature of this material enables simultaneous achievement of high permeability and high saturation flux density, resolving the contradiction between efficient flux conduction and saturation avoidance.
2Object-affected harmful factors
If ferrite is used in wireless charging systems, then magnetic shielding is provided, but heat generation increases affecting device performance
Solution Approach 1:
The patent changes the material parameters by using nanocrystalline material with superior magnetic properties including higher saturation flux density (Bs > 1.0 T) and higher permeability (μ > 10,000). This parameter change allows the material to handle higher magnetic flux without saturation, directly improving charging efficiency and preventing the saturation problem associated with conventional ferrite materials.
Solution Approach 2:
The patent employs nanocrystalline material as a composite alternative to conventional ferrite. This nanocrystalline material comprises fine-grained crystalline structures with specific compositional ratios (e.g., Fe-Si-B-Nb alloys) that provide enhanced magnetic properties. The composite nature of this material enables simultaneous achievement of high permeability and high saturation flux density, resolving the contradiction between efficient flux conduction and saturation avoidance.
3Volume of moving object
If device size is reduced, then form factor is improved, but available space for wireless charging materials is limited
Solution Approach 1:
The patent changes the material parameters by using nanocrystalline material with superior magnetic properties including higher saturation flux density (Bs > 1.0 T) and higher permeability (μ > 10,000). This parameter change allows the material to handle higher magnetic flux without saturation, directly improving charging efficiency and preventing the saturation problem associated with conventional ferrite materials.
Solution Approach 2:
The patent applies thin film technology by using nanocrystalline material in the form of thin foils or films with thicknesses optimized for compact device integration. These thin films provide the necessary magnetic shielding and flux conduction properties while occupying minimal space, enabling reduced device form factors without sacrificing wireless charging functionality.
4Ease of manufacture
If conventional materials are used, then manufacturing is simplified, but interference from external metal or magnetic materials occurs
Solution Approach 1:
The patent changes the material parameters by using nanocrystalline material with superior magnetic properties including higher saturation flux density (Bs > 1.0 T) and higher permeability (μ > 10,000). This parameter change allows the material to handle higher magnetic flux without saturation, directly improving charging efficiency and preventing the saturation problem associated with conventional ferrite materials.
Solution Approach 2:
The patent employs nanocrystalline material as a composite alternative to conventional ferrite. This nanocrystalline material comprises fine-grained crystalline structures with specific compositional ratios (e.g., Fe-Si-B-Nb alloys) that provide enhanced magnetic properties. The composite nature of this material enables simultaneous achievement of high permeability and high saturation flux density, resolving the contradiction between efficient flux conduction and saturation avoidance.
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 nanocrystalline foil maintains higher flux density saturation and permeability, reducing heat generation and interference, enabling faster charging and improved efficiency even in misaligned configurations, while adhering to regulatory frequency limits, thus overcoming the limitations of conventional materials.
Implementation Method 1
The nanocrystalline foil may be characterized by a permeability of greater than or about 1,000 μ0 at a thickness of the nanocrystalline foil of less than or about 250 μm
Implementation Method 2
The nanocrystalline foil may be configured to maintain a flux density below or about 50% of a saturation value when the wireless charging coil is receiving wireless power from a misaligned wireless power transmission coil
Implementation Method 3
an integrated circuit that may be configured to operate the wireless charging coil in a wireless charging transmission mode
Implementation Method 4
The integrated circuit may be further configured to receive wireless power using the wireless power coil and charge the battery using the received wireless power
Data Source
AI summary
Electronic devices according to embodiments of the present technology may include a battery. The devices may include a nanocrystalline foil. The devices may include a wireless charging coil seated on the nanocrystalline foil. The devices may also include an integrated circuit configured to operate the wireless charging coil in a wireless charging transmission mode.