`
`
`US 2009009641
`
`as) United States
`a2) Patent Application Publication (10) Pub. No.: US 2009/0096413 Al
`(43) Pub. Date:
`Apr. 16, 2009
`Partovi et al.
`
`(54)
`
`SYSTEM AND METHOD FOR INDUCTIVE
`CHARGING OF PORTABLE DEVICES
`
`(75)
`
`Inventors:
`
`Afshin Partovi, Sunnyvale, CA
`(US); Michael Sears, Ben Lomond,
`CA (US)
`
`Correspondence Address:
`FLIESLER MEYER LLP
`650 CALIFORNIA STREET, 14TH FLOOR
`SAN FRANCISCO, CA 94108 (US)
`
`(73)
`
`Assignee:
`
`MOJO MOBILITY, INC.,
`Sunnyvale, CA (US)
`
`(21)
`
`Appl. No.:
`
`12/116,876
`
`(22)
`
`Filed:
`
`May 7, 2008
`
`(63)
`
`(60)
`
`Related U.S. Application Data
`
`Continuation-in-part of application No. 11/669,113,
`filed on Jan. 30, 2007.
`
`Provisional application No. 60/763,816, filed on Jan.
`31, 2006, provisional application No. 60/810,262,
`filed on Jun.
`1, 2006, provisional application No.
`60/810,298, filed on Jun. 1, 2006, provisional applica-
`tion No. 60/868,674,filed on Dec. 5, 2006, provisional
`application No. 60/916,748, filed on May 8, 2007,
`provisional application No. 60/952.835, filed on Jul.
`30, 2007, provisional application No. 61/012,922,
`
`filed on Dec. 12, 2007, provisional application No.
`61/012,924, filed on Dec. 12, 2007, provisional appli-
`cation No. 61/015,606, filed on Dec. 20, 2007, provi-
`sional application No. 61/043,027, filed on Apr. 7,
`2008.
`
`Publication Classification
`
`(51)
`
`Int.Cl.
`HO02J 7/00
`
`(2006.01)
`
`(32) SM) vccccssncersetninangessesnusnennaevesnassevesanenenn Oe OF LOS
`
`(57)
`
`ABSTRACT
`
`Asystemand methodfor variable powertransfer in an induc-
`tive charging or power system.
`In accordance with an
`embodiment the system comprises a pad or similar base unit
`that contains a primary, whichcreates an alternating magnetic
`field. A receiver comprises a means for receiving the energy
`from the alternating magnetic field from the pad andtrans-
`ferring it to a mobile device, battery, or other device. In
`accordance with various embodiments, additional features
`can be incorporated into the systemto provide greater power
`transfer efficiency, and to allowthe systemto be easily modi-
`fied for applications that have different power requirements.
`These include variations in the material used to manufacture
`
`the primary and/orthe receivercoils; modified circuit designs
`to be used onthe primary and/or receiver side; and additional
`circuits and components that performspecialized tasks, such
`as mobile deviceor battery identification, and automatic volt-
`age or power-setting for different devicesor batteries.
`
`10
`
`112 Charger 116
`
`
`
`120
`
`Receiver” |'4
`
`ANKER 1006
`ANKER1006
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`1
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`
`
`Patent Application Publication
`
`Apr. 16,2009 Sheet 1 of 50
`
`US 2009/0096413 Al
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`100 ™,
`
`104
`
`104
`12Charger 7416|{120 Receiver” '"4
`
`FIG. 1
`
`2
`
`
`
`US 2009/0096413 Al
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`Apr. 16, 2009 Sheet 2 of 50
`
`Patent Application Publication
`
`
`FIG. 3
`
`FIG, 4
`
`3
`
`
`
`Patent Application Publication
`
`Apr. 16,2009 Sheet 3 of 50
`
`US 2009/0096413 Al
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`
`
`FIG. 5
`
`170
`
`™
`
`Capacitor
`176
`
`Rectifier a
`
`174
`
`172
`
`182
`
`FIG. 6
`
`4
`
`
`
`Patent Application Publication
`
`Apr. 16,2009 Sheet 4 of 50
`
`US 2009/0096413 Al
`
`190.
`
`Shell/Cover
`494
`
`200s,
`
`Replacement
`Shell/Cover
`210
`
`192
`
`P
`
`Jack
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`
`| W
`
`ith Original Shell
`
`FIG. 7
`
`220™
`
`234
`
`:
`Interconnects
`for Power/Data
`226
`
`228
`
`Communications/
`Storage Unit
`230
`
`5
`
`
`
`Patent Application Publication
`
`Apr. 16,2009 Sheet 5 of 50
`
`US 2009/0096413 Al
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`240—,
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`Charger
`
`Receiver
`
`
`FIG. 9
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` RFID
`Reader
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`6
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`Patent Application Publication
`
`Apr. 16,2009 Sheet 6 of 50
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`(escape wee
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`Regulator
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`1
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`Offset (Radius, r)
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`FIG. 12
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`Apr. 16,2009 Sheet 8 of 50
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`FIG. 15
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`FIG, 16
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`Apr. 16,2009 Sheet 9 of 50
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`FIG. 17
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`Apr. 16,2009 Sheet 10 0f50
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`Apr. 16,2009 Sheet 42 of 50
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`Patent Application Publication
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`Apr. 16,2009 Sheet 47 0f50
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`US 2009/0096413 Al
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`Apr. 16,2009 Sheet 48 0f50
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`Apr. 16,2009 Sheet 49 o0f50
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`US 2009/0096413 Al
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`Apr. 16,2009 Sheet 50 0f50
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`US 2009/0096413 Al
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`Apr. 16, 2009
`
`SYSTEM AND METHOD FOR INDUCTIVE
`CHARGING OF PORTABLE DEVICES
`
`CLAIM OF PRIORITY
`
`[0001] This application is a continuation-in-part of U.S.
`patent application Ser. No. 11/669,113, filed Jan. 30, 2007,
`titled “INDUCTIVE POWER SOURCE AND CHARGING
`SYSTEM”, whichapplication claims the benefit of U.S. pro-
`visional patent application 60/763,816, filed Jan. 31, 2006,
`titled “PORTABLE INDUCTIVE POWER SOURCE”; US.
`provisional patent application 60/810,262, filed Jun. 1, 2006,
`titled “MOBILE DEVICE, CHARGER, AND POWERSUP-
`PLY”: U.S. provisional patent application 60/810,298,filed
`Jun.
`1, 2006,
`titled “MOBILE DEVICE, BATTERY,
`CHARGING SYSTEM, AND POWER SUPPLY”; and U.S.
`provisional patentapplication 60/868,674,filed Dec. 5, 2006,
`titled “SYSTEM FOR PROVIDING A PORTABLE INDUC-
`
`TIVE POWER SOURCE”,this application also claims the
`benefit of U.S. provisional patent application 60/916,748,
`filed May 8, 2007, titled “CHARGING AND POWERING
`MOBILEDEVICES, BATTERIES”: U.S. provisional patent
`application 60/952,835, filed Jul. 30, 2007, titled “INDUC-
`TIVE CHARGING OF PORTABLE DEVICES”; U.S. pro-
`visional patent application 61/012,922, filed Dec. 12, 2007,
`titled “WIRELESS CHARGER WITH POSITION INSEN-
`
`SITIVITY™; U.S. provisional patent application 61/012,924,
`filed Dec. 12, 2007, titled “CONTROL, REGULATION,
`AND COMMUNICATION IN CHARGERS”; U.S. provi-
`sional patent application 61/015,606, filed Dec. 20, 2007,
`titled “PORTABLE INDUCTIVE POWER SOURCE”; and
`U.S. provisional patent application 61/043,027, filed Apr. 7,
`2008,
`titled “INDUCTIVE POWER SOURCE AND
`CHARGING SYSTEM”, this application is also related to
`copending U.S. patent application Ser. No. 11/757,067 filed
`Jun. 1, 2007, titled “POWER SOURCE, CHARGINGSYS-
`TEM, AND INDUCTIVE RECEIVER FOR MOBILE
`DEVICES”, each of which above applications are herein
`incorporated by reference.
`
`COPYRIGHT NOTICE
`
`[0002] A portion ofthe disclosure ofthis patent document
`contains material which is subject to copyright protection.
`The copyright owner has no objection to the facsimile repro-
`duction by anyone of the patent document or the patent dis-
`closure, as it appears in the Patent and Trademark Office
`patent file or records, but otherwise reserves all copyright
`rights whatsoever.
`
`FIELD OF INVENTION
`
`[0003] The inventionis related generally to power supplies,
`power sources, and particularly to a system and method for
`inductive charging of portable devices.
`
`BACKGROUND
`
`[0004] There is currently a need for powering portable or
`mobile devices for use in commercial, business, personal,
`consumer, and other applications. Examples of such devices
`include cellular
`telephones, personal digital assistants
`(PDAs), notebook computers, mobile email devices, Black-
`berry devices, Bluetooth headsets, hearing aids, music play-
`ers (for example, MP3 players), radios, compact disk players,
`video game consoles, digital cameras, walkie-talkie or other
`communication devices, GPS devices,
`laptop computers,
`
`electric shavers, and electric toothbrushes. Most of these
`devices include a rechargeable internal battery that must be
`first charged by an external power supply or charger, before
`the device itself can be used. The power supply typically
`provides direct current (DC) voltage through a special con-
`nector to the device. The power supply can then be discon-
`nected, and the device will continue to run for a short period
`of time until the battery is depleted. The voltage and power
`requirements of the different devices vary, andto date thereis
`currently no standardized connector for the devices, As a
`result of this, each mobile device is invariably sold ordistrib-
`uted bundled with its own charger. The costs associated with
`these multiple different types and numbers of charger are paid
`by the consumer indirectly by being incorporated into the
`prices being charged for the mobile device.
`[0005] The rapid increasein the total numberand variety of
`mobile products has meant that most people have several of
`the above-mentioned devices. In a typical day, that user would
`have to separately connect their multiple devices to each of
`their appropriate chargers for charging of each device. In
`addition, many people find it necessary to charge their devices
`in different locations such as their offices and cars. Thus,
`many users have purchased additional chargers for their
`offices and cars, for use in charging their mobile phones,
`notebook computers, and music players in those locations.
`[0006]
`It will be evidentthat the abovesituation has caused
`typical users to have a multitude ofincompatible devices (i.e.
`power supplies and chargers) that essentially provide the
`same functionof charging a mobile device, but because of the
`number and variety that must be kept by the user are incon-
`venient to use. In many situations, users simply forget to
`charge their devices, or else find they need to recharge their
`device in situations where no appropriate chargeris available.
`This leads to loss ofability to use the device whendesired or
`needed.
`
`In addition, whentraveling way from home, mobile
`[0007]
`users have a particular problem in that they need to pack and
`carry the multiple chargers for their devices. In many situa-
`tions, these chargers are bulkier and heavier than the devices
`themselves, and use of these devices in foreign countries
`requires clumsy adaptors, and sometimes voltage converters.
`This leads to a high degree of inconvenience for the ever-
`more-mobile consumer.
`
`In addition, the power connector for the mobile
`[0008]
`devices is often cheaply manufactured, and a source of
`mechanical andelectrical failure. In many applications, such
`as toothbrushesor applications where thedevice is exposed to
`water and needs to be hermetically sealed, such a physical
`connection can not be used. Thus an alternative means of
`powering those types of devices must be used.
`[0009]
`Several products have tried to addressthis situation.
`Some companies proposethe use of a universal charger that
`consists ofa power supply base unit, and interchangeabletips
`that bothfit into the base unit andin turn fit different devices.
`Thetip includes a customized regulator that sets the voltage
`required by the particular device. However, a user must carry
`the multiple tips he or she needs for each of the various
`devices they have, and then charge each deviceserially by
`connecting the device to the powersupply. While this product
`reduces the overall weight of the charging tools the user must
`carry, the user still needs to carry and exchange the tips to
`connect to different devices. In addition, the charging of
`multiple devices simultaneously is often not possible.
`
`52
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`Apr. 16, 2009
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`[0010] Realizing that a power supply typically contains a
`transformer for voltage conversion, another approach is to
`split the transformer into twoparts: a first part can contain the
`first winding and the electronicsto drive this windingat the
`appropriate operating frequency, while the second part con-
`sists of a winding where poweris received and thenrectified
`to obtain DC voltage. If the two parts are brought into physi-
`cal proximity to each other, power is transformed fromthe
`first part to the second inductively, i.e. by induction, without
`any physical electrical connection. This is the approachthatis
`used in many electrical toothbrushes, shavers, and other prod-
`ucts that are expected to be used in wet environments. How-
`ever, a commonproblem with such inductive units is that the
`windings are bulky, which restricts their use in lightweight
`portable devices. Furthermore, to achieve adequate power
`transfer, the parts must be designed tofit togethersuitably so
`that their windings are closely aligned. This is typically done
`by molding the device casing (for example, an electric tooth-
`brush) and its charger/holder so that they fit together in only
`one suitable way. However, the molded base and shapeof the
`portable device means they cannot be used in a universal
`fashion to powerother devices.
`[0011]
`Some companies have proposed pad-like charging
`devices based on inductive concepts,but that also ostensibly
`allow for different types of devicesto be charged. These pads
`typically include grids of wires in an x and y direction, that
`carry an electrical current, and that generate a uniform mag-
`netic field parallel to the surface ofthe pad. A receiver coil
`wound around a magnetic core lies on the surface ofthe pad
`and picks up the magnetic field parallel to the surface, and in
`this manner energy canbe transferred. However, each of these
`methods suffer from poor powertransfer, in that most of the
`powerinthe primary is not picked upin the receiver, and thus
`the overall power efficiency of the charger is very low. In
`addition, the magnetic cores used for the primary and receiver
`are often bulky and addto thetotal cost and size ofthe system,
`and limit incorporation into many devices.
`[0012] Another pointto note is that, while all of the above
`devices allow a user to charge a device, they also require the
`charging device or base unit to be electrically connected to a
`powersource, such as a poweroutlet ora DCsource. In many
`cases, the user may not have access to such a power source
`such as whentraveling, camping, or working in an area with-
`out access to power. However, to date, no device has been
`providedthatis portable, and that allows forinductive charg-
`ing of multiple devices with differing power requirements,
`and whichitself'can be intermittently or occasionally charged
`either by an external powersource, or by other means, orthat
`is self-powered or includes its own powersource.
`
`SUMMARY
`
`[0013] A portable inductive powersource, powerdevice,or
`unit, for use in powering or charging electrical, electronic,
`battery-operated, mobile, and other devices or rechargeable
`batteries is disclosed herein. In accordance with an embodi-
`ment the system comprises 2 parts: Thefirst part is a pad or
`similar base unit that contains a primary, which creates an
`alternating magnetic field by means ofapplying analternat-
`ing current to a winding,coil, or any type of current carrying
`wire. The second part of the system is a receiver that com-
`prises a means for receiving the energy fromthe alternating
`magnetic field from the pad and transferring it to a mobile or
`other device or rechargeable battery. The receiver may com-
`prise coils, windings, or any wire that can sense a changing
`
`magnetic field, and rectify it to produce a direct current (DC)
`voltage, which is then used to charge or power the device.
`[0014]
`In some embodiments the receiver can also com-
`prise electronic components or logic to set the voltage and
`current to the appropriate levels required by the mobile device
`or the charging circuit in the device, or to communicate infor-
`mationto the pad. In additional embodiments, the charging or
`powersystemcan provide for additional functionality such as
`communicationofdata stored in the electronic device or to be
`
`transferred to the device. Some embodiments may also incor-
`porate efficiency measures that improve the efficiency of
`power transfer between the charger and receiver, and ulti-
`mately to the mobile device or battery. In accordance with an
`embodimentthe charger or power supply includes aninternal
`battery for self-powered operation. In accordance with other
`embodiments the charger or power supply can include a solar
`cell power source, hand crank, or other means of power sup-
`ply for occasional self powered operation. Other embodi-
`ments can be incorporated into charging kiosks, automobiles,
`trains, airplanes, or other transport and other applications.
`[0015]
`In accordance with various embodiments, addi-
`tional features can be incorporated into the systemto provide
`greater powertransferefficiency, and to allow the systemto
`be easily modified for applications that have different power
`requirements. These include variations in the material used to
`manufacture the primary and/or the receiver coils; modified
`circuit designs to be used on the primary and/or secondary
`side; and additional circuits and components that perform
`specialized tasks, such as mobile device identification, and
`automatic voltage or power-setting for different devices.
`
`BRIEF DESCRIPTION OF THE FIGURES
`
`FIG. 1 shows a pad using multiple transmitter or
`[0016]
`charger coils in accordance with an embodiment.
`[0017]
`FIG. 2 shows a figure ofa circuit diagramin accor-
`dance with an embodiment.
`
`FIG. 3 shows a charging pad using multiple coils in
`[0018]
`accordance with an embodiment.
`
`FIG. 4 shows a charging pad using multiple over-
`[0019]
`lapping coil layers in accordance with an embodiment.
`[0020] FIG.5 shows the use of multiple coil types and sizes
`in overlapping pad layers in accordance with an embodiment.
`[0021]
`FIG. 6 shows a receiver with anintegrated battery in
`accordance with an embodiment.
`[0022]
`FIG. 7 showsa coupling of receiver with a deviceto
`be charged or powered in accordance with an embodiment.
`[0023]
`FIG. 8 shows a pad allowing modular or multiple
`connectivity in accordance with an embodiment.
`[0024]
`FIG. 9 shows a figure of a circuit diagramin accor-
`dance with an embodiment.
`
`FIG. 10 showsa figure of a circuit diagram in accor-
`[0025]
`dance with an embodiment.
`
`FIG. 11 showsa figure of a circuit diagram in accor-
`[0026]
`dance with an embodiment.
`
`FIG. 12 shows a figure of power transfer chart in
`[0027]
`accordance with an embodiment.
`
`FIG. 13 showsa figure ofa coil layout in accordance
`[0028]
`with an embodiment.
`
`FIG. 14 shows a figure ofa coil layout in accordance
`[0029]
`with an embodiment.
`
`FIG. 15 showsa figure of a charging pad with mul-
`[0030]
`tiple coils in accordance with an embodiment.
`
`53
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`
`Apr. 16, 2009
`
`FIG. 16 showsa figure of a charging pad with mov-
`[0031]
`able coils and two devices receiving poweror charge in accor-
`dance with an embodiment.
`[0032]
`FIG. 17 showsa figure of a circuit diagram inaccor-
`dance with an embodiment.
`[0033]
`FIG. 18 shows anillustration of a means ofstacking
`coils, in accordance with an embodiment.
`[0034]
`FIG. 19 shows a figure of a circuit diagram for
`identificationverification in accordance with an embodiment.
`
`FIG. 20 shows a figure of a circuit diagram for
`[0035]
`bidirectional communication in accordance with an embodi-
`ment.
`FIG. 21 shows a figure of a circuit diagram for
`[0036]
`output controller in accordance with an embodiment.
`[0037]
`FIG. 22 shows a figure ofa circuit diagram for the
`receiver with regulator in accordance with an embodiment.
`[0038] FIG.23 shows a figure ofa circuit diagram for MCU
`regulation in accordance with an embodiment.
`[0039]
`FIG. 24 shows a figure of a circuit diagram for
`unidirectional communication in accordance with an embodi-
`ment.
`
`FIG. 25 shows a figure ofa circuit diagram for
`[0040]
`time-based regulation in accordance with an embodiment.
`[0041]
`FIG. 26 shows a high level view ofa flyback power
`supply geometry in accordance with an embodiment.
`[0042]
`FIG. 27 shows an embodimentin which the output
`voltage to a load is monitored and with changes in the load
`condition, a chip ora Micro Controller Unit (MCU) varies the
`frequency or the duty cycle of the FETdriver to achieve
`optimumoperation.
`[0043]
`FIG. 28 shows an implementation of a charger in
`accordance with an embodiment, wherein the primary stage
`and the receiver stage communicate wirelessly.
`[0044]
`FIG. 29 shows an embodiment that includes Zero
`Voltage Setting (ZVS).
`[0045]
`FIG. 30 shows an embodimentin which, instead of
`a digital feedback circuit, an analog circuit based on coupling
`betweena light emitting diode (LED) anda light detector can
`be used.
`
`FIG. 31 shows an embodiment in which the opto-
`[0046]
`coupler is replaced by a Voltage Controlled Oscillator (VCO)
`and FETand in the primary, the signal is sent to adjust a
`frequency controller to provide optimumoutput voltage.
`[0047] FIG.32 shows an embodimentin whichthe wireless
`link can be analog or digital or can be integrated into the
`device to take advantage ofexisting wireless links in the
`device.
`
`FIG. 33 shows a basic schematic for an inductive
`[0048]
`single coil charging system in accordance with an embodi-
`ment.
`
`FIG. 34 shows the main components ofa wireless
`[0049]
`power/charging systemin accordance with an embodiment.
`[0050]
`FIG. 35 shows a typical experimental curve for
`powertransferred and Power Transfer in accordance with an
`embodiment.
`[0051]
`FIG. 36 shows an embodiment in which a coil
`mosaic is used to cover the surface area of a pad.
`[0052] FIG.37 shows an embodimentin which the number
`of drive (and sensing) circuits may be reduced by using elec-
`trical or electronic switches.
`
`FIG. 38 shows an embodiment in whichthree coil
`[0053]
`layer printed circuit board (PCB) is arranged to provide a
`cluster for uniform power in an area using only one coil
`powered at any given time.
`
`FIG. 39 shows an embodimentin whichthe coils are
`[0054]
`arranged such that by powering only one of the coils in the
`cluster, any receiver coil placed with a center within any
`locationin the effective area can receive the specified power
`if the appropriate chargercoil is activated.
`[0055]
`FIG. 40 shows an embodimentin which the number
`ofswitches required is reduced.
`[0056]
`FIG. 41 shows an embodiment of a multi-charger
`pad that incorporates a plurality of charging clusters.
`[0057]
`FIG. 42 shows an embodimentthat uses a cluster of
`two layers ofthree coils and a central coil to create an effec-
`tive area.
`FIG. 43 shows a mosaic of hexagonal coils with the
`[0058]
`central port to each coil shownas circles.
`[0059]
`FIG. 44 shows an embodiment of a MEMS pad
`including the top view.
`[0060]
`FIG. 45 shows an embodiment of a MEMS pad
`including a segmented MEMScharger pad.
`[0061]
`FIG. 46 shows an embodimentin which one or more
`regulated power supplies are connected to the charger pad.
`[0062]
`FIG. 47 shows anarray of contacts onthe surface of
`a pad in accordance with an embodiment.
`[0063]
`FIG. 48 showsthe side view of a MEMS conductive
`charger pad in accordance with an embodiment.
`[0064]
`FIG, 49 shows an embodiment wherein several
`regulated power supplies provide powerto the pad, to allows
`charging of several devices simultaneously.
`[0065]
`FIG. 50 showsanalternative embodimentof a pad
`using a segmented surface.
`[0066]
`FIG. 51 shows anindustry standard meansthat is
`used for measuring emissions froma product.
`[0067]
`FIG. 52 shows an embodiment whichillustrates
`absorption through a copper layer.
`[0068]
`FIG. 53 shows attenuation values for Copper and
`Aluminumlayers for several thicknesses.
`[0069]
`FIG. 54 shows transmitted power through Copper
`and Aluminum layers of varying thickness for an incident
`field at 1 MHz.
`[0070]
`FIG. 55 shows an embodiment which allows for
`obtaining local alignment independence betweencoils in the
`charger and the receiver.
`[0071] FIG.56 show an embodimentin which coil magnets
`can divided into sections.
`
`[0072] FIG.57 shows an embodimentin whichone or more
`alignment magnets can be used behind eachcoil.
`[0073]
`FIG. 58 showsanillustration of a device for induc-
`tive powercharging that includes an internal battery for sel{-
`