Multi-channel cooling for extended distance wireless power transmitter

Abstract

A power transmitter includes a transmitter antenna includes at least one coil configured to transmit the power signal to the power receiver, the at least one coil and a shielding comprising a ferrite core and defining a cavity, the cavity configured such that the ferrite core substantially surrounds all but the top face of the at least one coil. The power transmitter includes a housing configured for housing, at least, the transmitter antenna. The housing defines an airflow opening configured to provide an airflow to a first airflow channel and to a second airflow channel. The first and second airflow channels configured to provide the airflow to one or more of a top face of a mobile device thereon and a bottom face of the mobile device.

1 . A power transmitter for wireless power transfer to a power receiver, the power transmitter comprising:
 a transmitter coil array comprising:
 two or more transmitter coils configured to transmit a power signal to the power receiver, each of the two or more transmitter coils comprising at least one layer of Litz wire, and 
 a ferrite shielding structure comprising:
 two or more magnetic cores; 
 a magnetic backing; and 
 a magnetic wall, 
 wherein each of the two or more magnetic cores protrude from the magnetic backing and substantially fill an area interior of an innermost turn of one of the two or more transmitter coils, and wherein the magnetic wall substantially surrounds the two or more transmitter coils; and 
 
   a housing configured to house the transmitter coil array and support the power receiver for wireless power transfer from the transmitter coil array, the housing comprising:
 a forward surface configured for placement of the power receiver, the forward surface comprising:
 a first airflow channel configured to provide a first airflow between a portion of the forward surface and a rear surface of the power receiver. 
 
   
     
     
         2 . The power transmitter of  claim 1 , further comprising a fan positioned within a fan cavity of the housing, wherein the fan is configured to provide at least the first airflow to the first airflow channel. 
     
     
         3 . The power transmitter of  claim 1 , wherein the housing further comprises a second airflow channel configured to provide a second airflow to a front surface of the power receiver. 
     
     
         4 . The power transmitter of  claim 3 , further comprising a fan positioned within a fan cavity of the housing, wherein the fan is configured to provide at least the first airflow to the first airflow channel and the second airflow to the second airflow channel. 
     
     
         5 . The power transmitter of  claim 1 , wherein the magnetic wall and the magnetic backing define a cavity in the ferrite shielding structure, and wherein the two or more transmitter coils are positioned within the cavity of the ferrite shielding structure. 
     
     
         6 . The power transmitter of  claim 5 , wherein each of the two or more transmitter coils further comprise a top surface, a side surface, and a bottom surface, and wherein the magnetic backing and the magnetic wall substantially surround the bottom surfaces and the side surfaces of the two or more transmitter coils. 
     
     
         7 . The power transmitter of  claim 5 , wherein the magnetic backing defines at least a first plane and a second plane within the cavity in the ferrite shielding structure, wherein the two or more transmitter coils comprise at least a first transmitter coil in the first plane and a second transmitter coil in the second plane, and wherein the first transmitter coil and the second transmitter coil are offset and the first plane is above the second plane. 
     
     
         8 . The power transmitter of  claim 3 , wherein the first airflow channel is configured to mechanically receive a mechanical body associated with the power receiver, wherein receipt of the mechanical body, at least in part, aligns at least one of the two or more transmitter coils with a receiver antenna of the power receiver, for the purposes of wireless power transfer, and wherein the mechanical body is one or more of a mechanical feature of the power receiver, a peripheral associated with the power receiver, a removable feature associated with the power receiver, or any combinations thereof. 
     
     
         9 . The power transmitter of  claim 7 , wherein a portion of the first transmitter coil overlaps a portion of the second transmitter coil, and wherein at least a first portion of an outermost turn of the second transmitter coil is within a first area interior of an innermost turn of the first transmitter coil. 
     
     
         10 . The power transmitter of  claim 9 , wherein the two or more transmitter coils further comprise a third transmitter coil, wherein the third transmitter coil is within the first plane and overlaps a portion of the second transmitter coil, and wherein at least a second portion of the outermost turn of the second transmitter coil is within a third area interior of an innermost turn of the third transmitter coil. 
     
     
         11 . The power transmitter of  claim 10 , wherein the two or more magnetic cores comprise at least a first magnetic core, a second magnetic core, and a third magnetic core, wherein the first magnetic core substantially fills the first area, which is further defined by the innermost turn of the first transmitter coil and the first portion of the outermost turn of the second transmitter coil, wherein the second magnetic core substantially fills a second area defined by an innermost turn of the second coil, wherein the third magnetic core substantially fills the third area, which is further defined by the innermost turn of the third transmitter coil and the second portion of the outermost turn of the second transmitter coil, and wherein a top surface of the second magnetic core is in the first plane and a portion of the first transmitter coil and a portion of the third transmitter coil overlap the top surface of the second magnetic core. 
     
     
         12 . A power transmitter for wireless power transfer to a mobile device having a power receiver, the power transmitter comprising:
 a transmitter coil array comprising:
 two or more transmitter coils configured to transmit a power signal to the power receiver, each of the two or more transmitter coils comprising at least one layer of Litz wire, and 
 a ferrite shielding structure comprising:
 two or more magnetic cores; 
 a magnetic backing: and 
 a magnetic wall, 
 wherein each of the two or more magnetic cores protrude from the magnetic backing and substantially fill an area interior of an innermost turn of one of the two or more transmitter coils, and wherein the magnetic wall substantially surrounds the two or more transmitter coils; 
 
   a housing configured to house, at least, the transmitter coil array, the housing comprising:
 a top surface, upon which the mobile device is placed for wireless power transfer; 
 an airflow opening; 
 a first airflow channel configured to provide a first airflow, via the airflow opening, proximate to one or more of the top surface of the housing, a rear surface of the mobile device, or combinations thereof; and 
 a protrusion extending outward, at least in part, from the top surface, the protrusion comprising a protrusion side face that forms an angle with the top surface of the housing, the angle being less than about 180 degrees and greater than about 0 degrees. 
   
     
     
         13 . The power transmitter of  claim 12 , wherein the airflow opening is configured for fluid communication with an external airflow source, the external airflow source providing an external airflow to the airflow opening, and wherein the external airflow source is an airflow source operatively associated with a vehicle. 
     
     
         14 . The power transmitter of  claim 12 , wherein the housing further comprises a second airflow channel configured to provide a second airflow, via the airflow opening, to a front surface of the mobile device. 
     
     
         15 . The power transmitter of  claim 12 , wherein the housing further comprises a fan positioned in a fan cavity; wherein the fan is configured to provide at least a portion of the first airflow to the airflow opening. 
     
     
         16 . The power transmitter of  claim 12 , wherein the magnetic wall and the magnetic backing define a cavity in the shielding structure, and wherein the two or more transmitter coils are positioned within the cavity of the shielding structure. 
     
     
         17 . The power transmitter of  claim 16 , wherein each of the two or more transmitter coils further comprise a top surface, a side surface, and a bottom surface, and wherein the magnetic backing and the magnetic wall substantially surround the bottom surfaces and the side surfaces of the two or more transmitter coils. 
     
     
         18 . The power transmitter of  claim 17 , the magnetic backing defines at least a first plane and a second plane within the cavity in the ferrite shielding structure, wherein the two or more transmitter coils comprise at least a first transmitter coil in the first plane and a second transmitter coil in the second plane, and wherein the first plane and the second plane are offset and the first plane is above the second plane. 
     
     
         19 . A power transmitter for wireless power transfer to a mobile device having a power receiver, the power transmitter comprising:
 a control and communications unit;   an inverter circuit configured to receive input power and convert the input power to a power signal;   a transmitter coil array comprising:
 two or more transmitter coils configured to transmit the power signal to the power receiver, each of the two or more transmitter coils comprising at least one layer of Litz wire, and wherein each of the two or more transmitter coils comprise a top surface, a bottom surface, and a side surface; and 
 a ferrite shielding structure comprising:
 two or more magnetic cores; 
 a magnetic backing; and 
 a magnetic wall, 
 wherein the magnetic backing and the magnetic wall define a cavity configured such that the ferrite material substantially surrounds at least the bottom surfaces and the side surfaces of the two or more transmitter coils, and 
 wherein each of the two or more magnetic cores protrude from the magnetic backing and substantially fill at least a portion of an area interior of an innermost turn of one of the two or more transmitter coils; and 
 
   a housing configured to house, at least, the transmitter coil array, the housing comprising:
 a top surface, upon which the mobile device is placed for wireless power transfer, 
 an airflow opening, 
 a first airflow channel configured to provide a first airflow, via the airflow opening, proximate to one or more of the top surface of the housing, a rear surface of the mobile device, or combinations thereof. 
   
     
     
         20 . The power transmitter of  claim 19 , wherein the magnetic backing defines at least a first plane and a second plane within the cavity in the ferrite shielding structure, wherein the two or more transmitter coils comprise at least a first transmitter coil in the first plane and a second transmitter coil in the second plane, and wherein the first transmitter coil and the second transmitter coil are offset and the first plane is above the second plane.