DUAL-FREQUENCY WIRELESS CHARGER MODULES
20220407356 · 2022-12-22
Assignee
Inventors
Cpc classification
H02J50/005
ELECTRICITY
H02J50/402
ELECTRICITY
H02J7/0044
ELECTRICITY
H02J50/90
ELECTRICITY
International classification
H02J50/00
ELECTRICITY
H02J7/00
ELECTRICITY
Abstract
A transmitter coil module for inclusion in an accessory device can include a transmitter coil capable of operating at either of two different operating frequencies. The low frequency can be in a range from about 300 kHz to about 400 kHz, and the high frequency can be in a range from about 1 MHz to about 2 MHz. To provide efficient charging at both frequencies, the transmitter coil can be formed from a compound, or multi-stranded, wire. A control module can also be provided that is external to the transmitter coil module The control module can include, for example, a printed circuit board having control circuitry to generate alternating current in the transmitter coil at either the high frequency or the low frequency.
Claims
1. A transmitter coil module comprising: a housing including a cap and a housing base forming an enclosure; a coil formed of a compound wire wound into a plurality of turns, the coil being disposed in the enclosure, wherein the compound wire comprises a plurality of strands, wherein subsets of the strands are twisted around each other to form a set of basic bundles, wherein groups of basic bundles are twisted around each other to form a plurality of compound bundles, and wherein the plurality of compound bundles are twisted around each other to form the compound wire; and a plurality of contact pads exposed through an opening in the housing base, the plurality of contact pads including two contact pads that are electrically connected to a first end and a second end of the compound wire, wherein the coil is operable to generate an alternating current in the compound wire at a low frequency in a range between 300 kHz and 400 kHz and at a high frequency in a range between 1 MHz and 2 MHz.
2. The transmitter coil module of claim 1 wherein each basic bundle includes four strands.
3. The transmitter coil module of claim 2 wherein each compound bundle includes four basic bundles.
4. The transmitter coil module of claim 3 wherein the compound wire includes seven compound bundles.
5. The transmitter coil module of claim 1 wherein the plurality of turns of the compound wire are arranged in a single layer.
6. The transmitter coil module of claim 1 further comprising: a ferrimagnetic sleeve disposed around a distal surface of the coil; and an electromagnetic shield disposed between a proximal surface of the coil and the cap.
7. The transmitter coil module of claim 1 wherein the low frequency is 326 kHz and the high frequency is 1.78 MHz.
8. A wireless charging kit comprising: a transmitter coil module comprising: a housing including a cap and a housing base forming a sealed enclosure; a coil formed of a compound wire wound into a plurality of turns, wherein the compound wire comprises a plurality of strands, wherein subsets of the strands are twisted around each other to form a set of basic bundles, wherein groups of basic bundles are twisted around each other to form a plurality of compound bundles, and wherein the plurality of compound bundles are twisted around each other to form the compound wire; and a control module comprising a printed circuit board having electronic components mounted thereon, the electronic components including control circuitry configured to generate an alternating current in the compound wire at a low frequency in a range between 300 kHz and 400 kHz and at a high frequency in a 1-2 MHz range.
9. The wireless charging kit of claim 8 wherein each basic bundle includes four strands.
10. The wireless charging kit of claim 9 wherein each compound bundle includes four basic bundles.
11. The wireless charging kit of claim 10 wherein the compound wire includes seven compound bundles.
12. The wireless charging kit of claim 8 wherein the plurality of turns of the compound wire are arranged in a single layer.
13. The wireless charging kit of claim 8 wherein the transmitter coil module further comprises: a ferrimagnetic sleeve disposed around a distal surface of the coil; and an electromagnetic shield disposed between a proximal surface of the coil and the cap.
14. The wireless charging kit of claim 8 wherein the low frequency is 326 kHz and the high frequency is 1.78 MHz.
15. The wireless charging kit of claim 8 wherein the printed circuit board has a first plurality of contact pads for outputting AC current at a first end.
16. The wireless charging kit of claim 15 wherein the printed circuit board has a second plurality of contact pads for USB power and data at a second end opposite the first end.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
[0007]
[0008]
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DETAILED DESCRIPTION
[0014] The following description of exemplary embodiments of the invention is presented for the purpose of illustration and description. It is not intended to be exhaustive or to limit the claimed invention to the precise form described, and persons skilled in the art will appreciate that many modifications and variations are possible. The embodiments have been chosen and described in order to best explain the principles of the invention and its practical applications to thereby enable others skilled in the art to best make and use the invention in various embodiments and with various modifications as are suited to the particular use contemplated.
[0015]
[0016] A wireless charger accessory 150 can be used to provide power to electronic device 100 using inductive power transfer. For example, wireless charger accessory 150 can include a transmitter coil (not shown in
[0017] Efficiency of wireless power transfer depends on a number of factors, including alignment between the transmitter and receiver coils. In some embodiments, wireless charger accessory 150 and electronic device 100 can include magnetic alignment components (not shown in
[0018] In embodiments described herein, the transmitter coil of wireless charger accessory 150 can operate at either of two different operating frequencies, referred to herein as a “low” frequency and a “high” frequency. The low frequency can be in a range from about 300 kHz to about 400 kHz (e.g., about 326 kHz in some embodiments), and the high frequency can be in a range from about 1 MHz to about 2 MHz (e.g., about 1.78 MHz in some embodiments). Similarly, in embodiments described herein, the receiver coil of electronic device 100 can operate at either the high or low frequency. In some embodiments, the operating frequency for a particular pair of devices used together is determined dynamically, based on the capabilities of the devices. For example, it is contemplated that a family of electronic devices having similar form factors may be provided. The family may include “upgraded” electronic devices that can charge at either the high frequency or the low frequency, as well as “legacy” electronic devices that can charge only at the low frequency. Similarly, a family of wireless charger devices may include upgraded charger devices that can transmit power at either the high frequency or the low frequency and legacy charger devices that can transmit power only at the low frequency. An upgraded charger device can be used to provide power at the high frequency to an upgraded electronic device and to provide power at the low frequency to a legacy electronic device. Likewise, where an upgraded electronic device can receive power at either frequency, the upgraded electronic device can receive power at the high frequency from an upgraded charging device and can receive power at the low frequency from a legacy charging device. In this manner, upgraded electronic devices and chargers can be interoperable with legacy electronic devices and chargers.
[0019] Wireless charger accessory 150 can be any accessory that can be used with electronic device 100 and can have any form factor that may be desired. For instance, wireless charger accessory 150 can be a docking station for electronic devices and may also provide charging for other devices at the same time as electronic device 100 is being charged. To facilitate construction of different accessories that provide the same wireless charging performance, some embodiments provide a transmitter coil module (also referred to herein as a “wireless charger module”) that incorporates a transmitter coil and shielding and that has external electrical contacts via which alternating current can be provided to the transmitter coil. The external contacts can be coupled to a control module (e.g., a logic board) that includes the control circuitry to generate AC current for the transmitter coil. The transmitter coil module and control module can be integrated into a variety of accessories. Examples of transmitter coil modules and control modules will now be described.
[0020]
[0021] As shown in
[0022]
[0023] Ferrimagnetic sleeve 312 can be positioned at the distal side of coil 310 (i.e., the side opposite cap 204). Ferrimagnetic sleeve 312 can be made of ferrimagnetic material (which can be, e.g., a ceramic material that includes iron oxide) with a magnetic permeability (μ.sub.i) that provides low loss at high charging frequencies (e.g., ˜2 MHz). For example, the ferrimagnetic material can be MnZn with μ.sub.i˜900. Ferrimagnetic sleeve 312 can be shaped to direct magnetic flux generated by coil 310 toward charging surface 152 and can also provide shielding against electromagnetic emissions through surfaces of transmitter coil module 200 other than charging surface 152. The upper surface of ferrimagnetic sleeve 312 can be contoured to surround the distal and outboard side surfaces of coil 310. Ferrimagnetic sleeve 312 can have a central opening 317. A peripheral pass-through space 319 can be provided to accommodate coil terminals 311a, 311b. In some embodiments, electrically insulating material can be applied to portions of ferrimagnetic sleeve 312 to prevent ferrimagnetic sleeve from electrically contacting and shorting out charging coil 310.
[0024] Electromagnetic shield 314 can include a main shield body 315 disposed between cap 204 and coil 310 to provide a capacitive shield that helps to remove coupled noise between transmitter coil module 200 and an electronic device being charged by transmitter coil module 200, including noise that can occur as result of user interaction with a touch-sensitive display on the electronic device. In some embodiments, electromagnetic shield 314 can be made of thin and flexible materials. For example, electromagnetic shield 314 can be formed of a flexible printed circuit board with electrically-conductive material printed or otherwise deposited thereon. An adhesive layer (not shown) can be provided to secure electromagnetic shield 314 in place. In other embodiments, electromagnetic shield 314 can be formed by printing conductive material onto a pressure-sensitive adhesive film. As shown, main shield body 315 can include a slit 223 to prevent eddy currents from forming. Electromagnetic shield 314 can also include an L-shaped extension portion 316 that fits between ferrimagnetic sleeve 312 and housing base 202. Extension portion 316 can be electrically coupled to the main shield body 315. Extension portion 316 can attach to housing body 202 to provide electrical grounding. Second level 316 can have a printed circuit board 318 disposed on an underside thereof. Printed circuit board 318 can include the exposed electrical contacts 230 shown in
[0025] Magnet 322 and DC shield 324 can provide a magnetic alignment structure that can attract a complementary magnetic alignment structure in a portable electronic device to be charged. For example, magnet 322 can be a cylindrical permanent magnet with an axial dipole orientation. DC shield 324 can be made of a material that directs magnetic flux from magnet 322 away from the bottom surface of housing base 202 so that the distal side of transmitter coil module 200 is not strongly magnetized. The height of magnet 322 and DC shield 324 can be equal to a distance between cap 204 and the inner bottom surface of housing base 202, so that magnet 322 does not move axially within transmitter coil module 200 and so that the proximal end of magnet 322 is adjacent to the inner surface of cap 204. Lateral movement of magnet 322 can be constrained by the size of central opening 317 in ferrimagnetic sleeve 312 and/or using other techniques such as adhesives or potting.
[0026] Power can be supplied to transmitter coil module 200, and more particularly to coil 310, via contact pads 231-233 on the distal side of extension portion 316 of electromagnetic shield 314. In some embodiments, AC current from an external source is delivered directly to coil 210, and transmitter coil module 200 need not include any active electronic components.
[0027] Coil 310 can be capable of operating at high efficiency at two different fundamental frequencies. In some embodiments, the low frequency can be in a range from about 300 kHz to about 400 kHz (e.g., a frequency of 326 kHz), and the high frequency can be in a range from about 1 MHz to about 2 MHz (e.g., a frequency of about 1.78 MHz). As noted above, coil 310 can be formed from a conductive wire wound into multiple turns to form a coil. When alternating current flows through a conductor, the current density tends to be highest near the surface and decrease exponentially nearer the center of the conductor; this is referred to as the “skin effect.” Skin effect, which increases the effective resistance of the conductor, becomes more pronounced as frequency increases, resulting in less efficient operation.
[0028] To support efficient operation at high frequency, coil 310 in some embodiments can be made of a compound (multi-stranded) wire.
[0029] Coil 310 can be formed by winding multi-stranded wire 400 in multiple turns to form the desired coil shape. In some embodiments, coil 310 includes one layer of windings in a spiral pattern; however multiple layers of windings can be provided if desired. All windings can lie in the same plane, or coil 310 can have a non-planar shape, e.g., conforming to a concave or other non-planar charging surface 152 of cap 204. In some embodiments, the outer end of wire 400 can cross to the inside of coil 310 so that terminals 311a, 311b are both on the inboard side of coil 310 (as shown in
[0030] In embodiments described above, transmitter coil module 200 includes a charging coil 310 and external contact pads 231-233 that provide electrical connections directly to the coil but does not include a current source or active electronic components to drive or control current through the coil. In some embodiments, a control module can be provided separately from transmitter coil module 200, e.g., as part of a wireless charging kit. The control module can be, for example, a printed circuit board having mounted thereon electronic circuitry configured to drive the coil at the desired frequencies. The wireless charging kit can be supplied to a manufacturer of accessories, and the manufacturer of accessories can incorporate transmitter coil module 200 and the control module into an accessory. Examples of a control module for transmitter coil module 200 will now be described.
[0031]
[0032] A “proximal” end 520 of logic board 502 can include contact pads 521-523 to deliver output current for transmitter coil module 200. For example, contact pads 521-523 can include AC hot, neutral, and ground pads. A three-wire cable can be connected between contact pads 521-523 and contact pads 231-233 of transmitter coil module 200 to provide AC current to coil 310 as well as grounding of housing base 202 and electromagnetic shield 314.
[0033] A “distal” end 530 of logic board 502 (opposite proximal end 520) can include contact pads 531-540. In some embodiments, contact pads 531-540 can include contacts supporting standard USB connections. For example, contact pads 531-534 can correspond to USB bus voltage, D+ and D− data signals, and ground, and contact pads 535 and 538 can correspond to USB CC pins (used for USB Type-C connections). Contact pads 531-540 can be castellated to facilitate connections to a USB plug-type connector.
[0034] Distal end 530 of logic board 502 can be connected to various devices via which power (e.g., DC power complying with USB standards) and optionally data can be provided to logic board 502.
[0035] Further illustrating how a control module can be incorporated into a wireless charger accessory,
[0036] In embodiments described above, a wireless charger accessory incorporating transmitter coil module 200 can operate coil 310 to provide power at either a low frequency (e.g., a frequency of about 326 kHz or other frequency in the range from about 300 kHz to about 400 kHz) or a high frequency (e.g., a frequency of about of 1.78 MHz or other frequency in the range from about 1.5 MHz to about 2 MHz). In some embodiments, power transfer efficiency to a particular electronic device can be around 70% at the low frequency and around 85% at the high frequency. The coil configurations described above provide more efficient magnetic coupling at the high frequency than the low frequency, although the associated electronics may operate slightly less efficiently at the high frequency. In some embodiments, the increased magnetic coupling efficiency at the high frequency can result in significant reductions (e.g., 25% to 50%) in time needed to charge a battery of a portable electronic device at the high frequency as compared to charging at the low frequency. In some embodiments, transmitter coil module 200 operates at the high frequency when providing power to a device capable of receiving power at the high frequency and switches to the low frequency when providing power to other devices (e.g., legacy devices as described above).
[0037] In some embodiments, a manufacturer can provide a kit that includes a transmitter coil module (e.g., transmitter coil module 200) and a control module (e.g., logic board 502) as separate, disconnected components. A third party can assemble a wireless charging accessory by connecting logic board 502 to transmitter coil module 200 (e.g., using wires as described above) and enclosing transmitter coil module 200 and logic board 502 in an accessory housing such that charging surface 152 of transmitter coil module 200 is exposed. The accessory housing can have any form factor desired. For example, the housing can follow the puck shape of transmitter coil module 200, and a cable extending therefrom can have a boot that houses logic board 502 (e.g., as shown in
[0038] While the invention has been described with reference to specific embodiments, those skilled in the art will appreciate that variations and modifications are possible. For instance, the transmitter coil module and control module described herein are designed to be compact to fit within accessories having small form factors. The control module can be provided as a printed circuit board with components (e.g., integrated circuits and/or circuit components) mounted thereon, or the circuit board can be enclosed, e.g., within a metal structure such as a Faraday cage that provides electromagnetic shielding and physical protection for the components. A wireless power module and control module of the kind described herein can be incorporated into a variety of accessory devices to provide wireless charging capability, regardless of form factor or other functionality of the accessory device. All dimensions and materials mentioned herein are for purposes of illustration and can be modified. The number of strands in a bundle and number of bundles in a wire can also be varied. Using twisted strands to form a compound wire can simplify manufacturing.
[0039] Accordingly, although the invention has been described with respect to specific embodiments, it will be appreciated that the invention is intended to cover all modifications and equivalents within the scope of the following claims.