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`a2) Patent Application Publication 10) Pub. No.: US 2008/0116847 Al
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` Lokeet al. (43) Pub. Date: May 22, 2008
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`(21) Appl. No.:
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`4.
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`(22)
`Filed:
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`(54) SYSTEMS AND METHODS FOR WIRELESS
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`POWER TRANSFER
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`Siew Ling Loke, London (GB);
`Inventors:
`Eng Hua Lee, London (GB); Raif
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`M.Awaida, London (GB)
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`Correspondence Address:
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`IRVINE. CA 92614 ’
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`(73) Assignee:
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`» Tortola (VG)
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`11/844,242
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`Aug. 23, 2007
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`Related U.S. Application Data
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`(60) Provisional application No. 60/950,192, filed on Jul.
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`17, 2007, provisional application No. 60/841,759,
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`filed on Sep. 1, 2006, provisional application No.
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`60/894,581, filed on Mar. 13, 2007.
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`Publication Classification
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`(51)
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`(52) US. CD. veces creseneeeseceneees 320/108; 307/104
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`ABSTRACT
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`Systems and methods for wireless power transfer are dis-
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`closed. Primary windings generate magnetic fields which are
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`inductively coupled to secondary windingsto transfer power
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`in a Wireless manner. One embodimentincludesa plurality of
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`tiles of magnetic cores and windings for the primary wind-
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`ings. The tiles can be arranged in a magnetic segment with
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`windingsoftiles being orthogonalwith respect to windings of
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`adjacenttiles. For example, a winding ofa first tile can be
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`horizontal, and windingsof adjacenttiles can be vertical. One
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`embodiment further groups these magnetic segments into
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`larger entities, wherein each magnetic segment can be inde-
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`pendently activated. One embodiment includes a magnetic
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`amplifier or an electronic device for secondary side control of
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`power. This permits multiple devices to be powered or
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`Page 1 of 36
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`POWER TRANSFER
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`CROSS-REFERENCE TO RELATED
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`APPLICATIONS
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`[0001] This application claimsthe benefit under 35 U.S.C.
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`§ 119(e) of U.S. Provisional Application No. 60/841,759,
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`filed on Sep. 1, 2006; U.S. Provisional Application No.
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`60/894,581, filed on Mar. 13, 2007; and U.S. Provisional
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`Application No. 60/950,192, filed on Jul. 17, 2007, the entire
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`disclosures of which are hereby incorporated by reference.
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`[0002] This application is related to copending application
`titled THREE-DIMENSIONAL ELECTROMAGNETIC
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`[Attorney
`FLUX FIELD GENERATION,Ser. No.
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`Docket No. RAIF.004A], filed on the samedate as the present
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`application, the entirety of which is hereby incorporated by
`reference.
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`BACKGROUND OF THE INVENTION
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`1. Field of the Invention
`[0003]
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`[0004] The invention generally relates to electronics, and in
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`particular, to wireless charging.
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`2. Description of the Related Art
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`[0006]
`Portable devices has proliferated over the past ten
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`years. For the purpose of cost and convenience these devices
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`rely on secondary powercells which can be recharged for
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`example laptop computers, mobile telephones, electrical
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`toothbrushes, shavers and personaldigital assistant. Many of
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`these devices are charged via electrical contacts and power
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`supplies that take power from the mains and convert into a
`level suitable for each individual device.
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`[0007] Conventional techniques for power conversion and
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`electrical connection vary considerable from manufacturer to
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`manufacturer. Therefore, for consumers who ownseveral of
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`these devices are required to own or carry around several
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`different types of adaptors which can be cumbersome when
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`traveling or trying to find enough sockets to plug them into.
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`Moreover, these devices have open electrical contacts that can
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`be damagedin water or exposed to other chemicals and there-
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`fore inappropriate to be used by hard wearing users. In recent
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`years, some attempts have been made to overcomethe fore-
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`seeable problems.
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`Inductive transference of energy or power has been
`[0008]
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`used for many years in the form of transformers in switched
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`mode power supplies. They include a primary circuit that
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`generates electromagnetic flux field and fixed secondary cir-
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`cuits those receive inductively coupled power.
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`[0009] Wireless power transfer has becomea very attrac-
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`tive solution with the proliferation of portable devices over
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`the past ten years. With these devices for instant mobile
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`phones, toothbrushes, PDA or laptop computers reliant on
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`rechargeable secondary poweredcells, it may not always be
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`convenient or safe to have open electrical contacts. The wire-
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`less connection provides a number of advantages over con-
`ventional hardwired connections. A wireless connection can
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`reduce the chance of shock and can providea relatively high
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`level of electrical isolation between the power supply circuit
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`and the secondary circuit. Inductive couplings can also make
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`it easier for a consumerto replace limited-life components.
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`Secondary devices can be completely sealed to ensure safety
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`when used in damp or wet surroundings for example bath-
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`room,kitchen or even swimmingpool. This wireless solution
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`is not only limited to portable devices. Many devices like
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`Page 28 of 36
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`game consoles, DECT phonesor even a lamp can benefit from
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`cutting the cords. As there many wireless communication
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`platforms that already exist or upcoming like Bluetooth,
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`NFC, WIFI, UWB, GSMetc., the only physical connection
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`left is the power supply.
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`[0010] Wireless inductive charging of portable devices is
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`divided into two categories. The first category is indirect
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`charging, where the wireless electronics supplies power to
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`secondary ofthe charging circuitry of a portable device which
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`in turn will charge its battery accordingly. The secondcat-
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`egory is direct charging, where the secondary of the wireless
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`inductive charging electronics are connected (contacted) to
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`the battery directly supplying the charging current. Direct
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`charging is typically moreefficientas it has less circuitry for
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`powerloss to occur. However, direct charging is physically
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`difficult to implementusing wireless technology on existing
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`portable devices. Many portable or handheld devices are built
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`to a compactspecification. Portable devices typically do not
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`have room for any additional circuitry.
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`[0011]
`Prior techniques of non-contact battery charging
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`include a technique whereby an inductive coil on the primary
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`side aligns with a horizontal inductive coil on a secondary
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`device when the deviceis placed into a cavity on the primary
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`side that ensures precision in the alignment, whichis crucial
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`to achieving effective powertransfer. A device that uses this
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`technique includes the Braun Oral B Plak Control toothbrush.
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`However, this system requires the secondary devices to be
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`axially aligned with the primary unit. Existing wireless charg-
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`ers are typically also uniquely designed by each individual
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`manufacturer and typically cannot be used interchangeably.
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`[0012] Examples of wireless power transfer include U.S.
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`Pat. No. 3,938,018 to Dahl; U.S. Pat. No. 5,959,433 to Rohde;
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`USS. Pat. No. 4,873,677 to Sakamoto, et al.; U.S. Pat. No.
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`5,952,814 to Van Lerberghe; U.S. Pat. No. 6,208,115 to
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`Binder, WO 00/61400; WO 95/11545; GB2399225;
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`GB2399226; GB2399227; GB2399228; GB2399229;
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`GB2399230; U.S. Pat. No. 5,519,262 to Wood; U.S. Pat. No.
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`5,703,461 to Minoshima, et al.; U.S. Pat. No. 6,906,495 to
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`Cheng,et al.; U.S. Pat. No. 7,123,450 to Baarman,et al.; U.S.
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`Pat. No. 4,675,615 to Bramanti; U.S. Pat. No. 5,952,814 to
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`Van Lerberghe; U.S. Pat. No. 7,211,986 B1 to Flowerdew et
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`al.; and U.S. Pat. No. 7,215,096 B2 to Miura et al.
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`SUMMARY OF THE INVENTION
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`[0013] Embodiments of the invention can resolve the mat-
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`ter of cost, size and efficiency. Embodiments can be modular
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`giving the possibility of for user to customizeto their require-
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`ments with ease. It is flexible, where it can be mould to any
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`shapesandsizes. It is also intelligent, it can detect when and
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`where power is used, keeping auxiliary power losses to the
`minimum.
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`[0014] A first embodimentis used as a battery charger to
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`recharge a system of biometrics security card for used in
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`airports. The primary is assembly can be mould onto the
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`dashboardofvehicles, staff desks andticketing or reservation
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`counters using anti slip material as the surface. The secondary
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`is mounted to the biometrics security card which has to be
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`intrinsically safe. Multiple cards can be charged at the same
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`time. The cards can be charged regardless of their orientation
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`due to the rotating magnetic field produced by a thin 2-di-
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`mensional surface using a single layer multi-filar stacking
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`technique.
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`[0015] Asecond embodimentis used asa single or multiple
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`mobile phones charger. With a minute secondary charging
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`US 2008/0116847 Al
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`May 22, 2008
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`tery packs themselves. By integrating the secondary unit of a
`circuit placed within the mobile phone, the phone can be
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`charged when placed in the vicinity of the magnetic field
`contactless charger into the battery packs themselves, all a
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`regardless of orientation. The charging surface can be cus-
`consumer would need to do to embrace the wireless power
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`tomized to the size used. In the event when the charging
`technologyis to replace the battery packs.
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`surface is larger than the required area of the mobile phone,
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`[0024] There can be other aspects of an embodimentof the
`the inductive power transfer will be localized to the device
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`invention. Apart from incorporating the winding coils and the
`itself. This aspect reduces unnecessary power generation and
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`electronic circuitries into battery packs, there is also the adap-
`its resulting losses.
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`tive control technique called parameter scheduling used for
`[0016] One aspect is ina flexibility which is achieved using
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`optimizing the powertransfer. This technique is designed in
`micro-tiles high permeability ferrites to form the magnetic
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`core used as the charging surface. This charging surface is
`sucha waythat a universal control algorithm can be employed
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`poweredas the primary ofthe of the magnetic flux field with
`for battery types of varying characteristics, such as, but not
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`powerelectronics circuitry.
`limited to, lithium polymer, lithium ion, nickel-cadmium,
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`[0017] A second aspect is in this powercircuitry, where
`nickel metal hydride, or the like.
`anti-saturation reset inductive toroidal cores are used should
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`[0025] Another aspect is introduction of a component; a
`the primary experience a phenomenoncalled the staircase
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`saturable inductor commonly known as a magnetic amplifier
`saturation, which is normally the main reason for component
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`in the secondary ofthe charging electronics. In one embodi-
`failures. This technique prevents heating of the ferrite cores
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`ment, an electronic switch such as a MOSFET anda post
`and as a result smaller and lower rated components can be
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`used.
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`regulating control circuit replaces the saturable inductor.
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`[0018] A third aspect is in the winding technique where a
`These components can render the control of the secondary
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`single layer multi-filiar technique is usedto achieve a rotating
`unit independent of the primary charging surface. This fea-
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`magnetic flux field with the assistance of a unique power
`ture is particularly useful in the event when multiple devices
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`circuitry design. This rotating field is what enables the power
`are being charged on the same primary surface.
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`transference to occur successfully regardlessof orientation of
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`[0026] One embodimentis an apparatusfor providing wire-
`the secondary assembly.
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`less charging, wherein the apparatus includes: a magnetic
`[0019]
`<A fourth aspect is modularity, where a virtually
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`unlimited numberofmicro-tiles can be stacked or removed in
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`segment of 2 or more tiles, each tile having at least one
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`winding having at least one turn, each time having a core of
`segments without drastically changing the operation charac-
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`high magnetic permeability material, the magnetic segment
`teristics. This is useful when expansion is required.
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`having at least a first group of one or more tiles having
`[0020] One embodimenthas the intelligence to know if a
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`secondary deviceis present using Near Field Communication
`winding(s) oriented inafirst direction and a second group of
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`(NFC). If a device is not present, the magnetic field on the
`one or more tiles having winding(s) oriented in a direction
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`charging surface will seize enters a standby mode. It will be
`different than the first direction; and an inverter configured to
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`powered up again when a secondary device is placed in the
`powerthe windingsofthe tiles. In one embodiment, the gap
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`vicinity of the field. With this feature, it also allowslocalized
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`is between about 0.5 mm and 2 mm.In one embodiment, the
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`charging. As mentioned before, due to the micro-tiles con-
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`core is about 5 mm to about 30 mm in length and/or width.
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`figuration and the unique winding technique,the larger charg-
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`[0027] One embodimentis a methodof providing wireless
`ing surfaces are divided into various segments. These seg-
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`charging, wherein the method includes: generating an AC
`ments can be controlled separately and only the area thatis
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`magnetic field from a magnetic segment, the magnetic seg-
`required will have a magnetic field available for inductive
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`ment comprising 2 or more tiles, each tile having at least one
`powertransfer. These segments can have adjustable field
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`winding having at least one turn, each time having a core of
`strengths to meet a variety of device power requirements.
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`high magnetic permeability material, the magnetic segment
`In one embodiment, the wireless electronics for
`[0021]
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`having at least a first group of one or more tiles having
`charging of one or more battery cells is integrated with the
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`winding(s) oriented inafirst direction and a second group of
`cells into a battery pack. This permits a consumer has to
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`procure these battery packs to render their portable device
`one or more tiles having winding(s) oriented in a direction
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`compatible with wireless inductive charging. This is also
`different thanthefirst direction; and generating AC current to
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`good for manufacturers, as a wireless inductive charging fea-
`powerthe windingsofthetiles.
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`ture can be provided by incorporating the charging circuitries
`[0028] One embodimentis an apparatus for receiving wire-
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`into the battery packs.
`less powertransfer, wherein the apparatus includes: a wind-
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`[0022] One embodimentof the inventionis a battery pack
`ing configured to inductively couple power in a wireless
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`that includes winding coils that receive power and charging
`manner; a regulating device disposed in a current path of the
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`electronics. The battery pack can be used with a magnetic
`winding; a rectifier circuit configured to rectify alternating
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`amplifier that performs closed loop control that is indepen-
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`current from the winding; and a control circuit configured to
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`dent of the primary charging device.
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`control operation of the regulating device for regulation ofat
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`[0023] One embodiment of the invention harnesses an
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`least one of voltage, current, or power received from the
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`inductive or contactless power transfer technique for charg-
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`winding.
`ing rechargeable battery packs. In a secondary unit, poweris
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`[0029] One embodimentis a methodfor receiving wireless
`received wirelessly through magnetic induction from a pri-
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`powertransfer, wherein the method comprising: wirelessly
`mary unit. This secondary unit includes coil windings and
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`inductively coupling to a source of power, thereby generating
`electronic circuitries can be installed into various types of
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`an internal source of alternating current; controlling a regu-
`portable devices where battery charging takes place. One
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`feature is the embedmentof the secondary unit into the bat-
`lating device or an electronic circuit disposed ina current path
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`Page 29 of 36
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`Page 29 of 36
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`

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`US 2008/0116847 Al
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`May 22, 2008
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`of the alternating current to regulate at least one of power,
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`voltage, or current; and rectifying the alternating current.
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`BRIEF DESCRIPTION OF THE DRAWINGS
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`[0030] These drawings and the associated description
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`herein are providedto illustrate specific embodiments of the
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`invention andare not intendedto be limiting.
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`FIG. 1 illustrates an embodiment of a base station
`[0031]
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`system for wireless powertransfer.
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`FIG.2 illustrates an example of an inverter circuit.
`[0032]
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`[0033]
`FIG. 3 illustrates an example of an anti-saturation
`inductor.
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`FIG.4Aillustrates an exampleofthe inverter circuit
`[0034]
`with the anti-saturation inductor.
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`[0035]
`FIG. 4B illustrates an example of a secondary cir-
`cuit.
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`FIG. 24 illustrates an example of an electronic post
`[0057]
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`regulating circuit, which can be used in place of a magnetic
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`amplifier.
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`DETAILED DESCRIPTION OF THE PREFERRED
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`EMBODIMENT
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`[0058] One embodimentis directed to a new generation is
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`wireless powertransfer. FIG. 1 illustrates one embodiment.
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`The primary-side magnetic surface includes a mosaic ofhigh-
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`permeability micro-tiles. Cores for the micro tiles can be
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`made from a high permeability material, such as ferrite. Other
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`materials can be used. In one embodiment, the relative per-
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`meability of the material for the coreis at least 20.
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`[0059] The use of 12 tiles is forillustrative purposes andis
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`not intendedto be limiting. These tiles can vary in size, for
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`example, between 3-5 mm in thickness, and 10-20 mm in
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`length and width. These dimensionsare intendedto be illus-
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`trative and not necessarily limiting. These micro-tiles form a
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`magnetic segment 102 or array of micro-tiles. This segment
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`102 is powered by a switched mode power electronics cir-
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`cuitry, which includes an inverter 104 and a control system
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`106. The switched mode powerelectronics circuitry in turn
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`receives a DC input from the mains adapter 108 which plugs
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`directly into a 100-240V mains socket (typically AC). The
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`illustrated embodimentis based on the operation of switched
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`mode powersupplies.
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`[0060]
`FIG. 2 illustrates an example of an invertercircuit
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`(104 FIG.1). It has a double push-pull configuration which,in
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`the illustrated embodiment, includes two separate push pull
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`circuits 1020 and 1021 respectively sharing the same DC
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`source. The illustrated transformer’s primary windings 1000
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`and 1001 are of a center-tapped topology. Other topologies
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`are applicable. One advantage of the push-pull circuit is that
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`there is typically only one switch conducting at any instant of
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`time, as opposed to multiple switches in series. This can be
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`useful if the DC input to the converter is from low voltage
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`source, where the voltage drops across more than one switch
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`in series would result in a significant reduction in energy
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`efficiency. Another advantageis that the controldrives for the
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`two switches have a common ground.
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`[0061] A possible disadvantage of this configuration is the
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`possibility of DC saturation of the magnetic cores, which is
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`overcomeby introducingthe anti-saturation inductorscircuit
`200a@ and 2005 shown in FIGS. 2 and3. In the illustrated
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`embodiment, in the event of imbalance betweenthe push-pull
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`magnetic cores, a DC voltage will be built up across the
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`anti-saturation choke/inductor thereby saturating it. The fly-
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`back action on the secondary of the choke will return the
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`energy stored to prevent the saturation. The purpose of the
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`double push-pull topology is to individually control two sepa-
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`rate sets ofcore windingsas will be explained in the following
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`paragraph about the magnetic cores arrangements. A more
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`detailed circuit diagram of the inverter with the anti-satura-
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`tion inductor applied to the center-tap ofthe primary winding
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`is illustrated in FIG. 4A. Other topologies are applicable and
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`will be readily determined by one ofordinary skill in theart.
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`[0062]
`FIG. 4B illustrates an example of a secondary cir-
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`cuit. The secondary floating unit that is to be installed in
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`various types of portable devices includes a magnetic ampli-
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`fier 440, a rectifying circuit, microcontroller and a current
`source circuit will be described in further detail later in con-
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`nection with FIG. 19. The secondary floating unit can include
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