LI JIE (US)
QIN RUIYANG (US)
US20210193381A1 | 2021-06-24 | |||
US20200090855A1 | 2020-03-19 | |||
US20190081517A1 | 2019-03-14 | |||
US20140340031A1 | 2014-11-20 | |||
CN108270078B | 2020-08-14 |
CLAIMS What is claimed is: 1. A series self-resonant coil structure for wireless power transfer, the coil structure comprising: a first conductive layer configured in a first planar spiral arrangement, the first conductive layer comprising a first terminal; a second conductive layer configured in a second planar spiral arrangement, the second conductive layer comprising a second terminal; and a dielectric layer positioned between the first conductive layer and the second conductive layer; wherein the first conductive layer, the second conductive layer, and the dielectric layer are configured to produce a repeated serial LC connection between the first terminal and the second terminal; and wherein the first conductive layer comprises at least one discontinuity and the second conductive layer is continuous at the location of the at least one discontinuity mirrored about the dielectric layer. 2. The coil structure of claim 1, comprising a plurality of parasitic capacitors connected to the first conductive layer and to the second conductive layer and configured to compensate the voltage potential of one or more portion of the first planar spiral arrangement and the second planar spiral arrangement. 3. The coil structure of claim 2, wherein the plurality of parasitic capacitors are positioned at alternating turns of the first conductive layer and of the second conductive layer. 4. The coil structure of claim 2, wherein the plurality of parasitic capacitors are positioned at each half turn of the first conductive layer and the second conductive layer. 5. The coil structure of claim 1, wherein the first conductive layer and the second conductive layer comprise interleaved symmetric structures. 6. The coil structure of claim 1, comprising: one or more additional conductive layer configured in a planar spiral arrangement; and one or more additional dielectric layers positioned between the one or more additional conductive layer and an adjacent conductive layer. 7. The coil structure of claim 1, comprising a ferrite shield arranged on a side of the first conductive layer opposite the dielectric layer, the ferrite shield being configured to protect magnetic coupling and reduce interference with neighboring objects. 8. The coil structure of claim 1, comprising an alternating current source connected to the first terminal and the second terminal. 9. A system for wireless power transfer, the system comprising: a power source; a transmitter coil; and a control circuit configured for wirelessly supplying power to a receiving device by applying power from the power source to the transmitter coil; wherein the transmitter coil comprises a series self-resonant coil structure comprising: a first conductive layer configured in a first planar spiral arrangement, the first conductive layer comprising a first terminal; a second conductive layer configured in a second planar spiral arrangement, the second conductive layer comprising a second terminal; and a dielectric layer positioned between the first conductive layer and the second conductive layer; wherein the first conductive layer, the second conductive layer, and the dielectric layer are configured to produce a repeated serial LC connection between the first terminal and the second terminal; and wherein the first conductive layer comprises at least one discontinuity and the second conductive layer is continuous at the location of the at least one discontinuity mirrored about the dielectric layer. 10. The system of claim 9, comprising a plurality of parasitic capacitors connected to the first conductive layer and to the second conductive layer and configured to compensate the voltage potential of one or more portion of the first planar spiral arrangement and the second planar spiral arrangement. 11. The system of claim 10, wherein the plurality of parasitic capacitors are positioned at alternating turns of the first conductive layer and of the second conductive layer. 12. The system of claim 10, wherein the plurality of parasitic capacitors are positioned at each half turn of the first conductive layer and the second conductive layer. 13. The system of claim 9, wherein the first conductive layer and the second conductive layer comprise interleaved symmetric structures. 14. The system of claim 9, comprising: one or more additional conductive layer configured in a planar spiral arrangement; and one or more additional dielectric layers positioned between the one or more additional conductive layer and an adjacent conductive layer. 15. The system of claim 9, comprising a ferrite shield arranged on a side of the first conductive layer opposite the dielectric layer, the ferrite shield being configured to protect magnetic coupling and reduce interference with neighboring objects. 16. The system of claim 9, wherein the power source comprises an alternating current source connected to the first terminal and the second terminal. 17. A method for wireless power transfer, the method comprising: detecting initiation of wireless power transfer to a receiving device; and applying power from a power source to a transmitter coil, wherein the transmitter coil comprises a series self-resonant coil structure comprising: a first conductive layer configured in a first planar spiral arrangement, the first conductive layer comprising a first terminal; a second conductive layer configured in a second planar spiral arrangement, the second conductive layer comprising a second terminal; and a dielectric layer positioned between the first conductive layer and the second conductive layer; wherein the first conductive layer, the second conductive layer, and the dielectric layer are configured to produce a repeated serial LC connection between the first terminal and the second terminal; and wherein the first conductive layer comprises at least one discontinuity and the second conductive layer is continuous at the location of the at least one discontinuity mirrored about the dielectric layer. 18. The method of claim 17, wherein transmitter coil comprises a plurality of parasitic capacitors connected to the first conductive layer and to the second conductive layer and configured to compensate the voltage potential of one or more portion of the first planar spiral arrangement and the second planar spiral arrangement. 19. The method of claim 18, wherein the plurality of parasitic capacitors are positioned at alternating turns of the first conductive layer and of the second conductive layer. 20. The method of claim 18, wherein the plurality of parasitic capacitors are positioned at each half turn of the first conductive layer and the second conductive layer. |
where k is integer starting from 3. 3. Coil EST The total loss of the self-resonant coil include copper loss and dielectric loss. The copper loss can be modeled as skin-effect loss plus proximity effect loss. The skin effect loss is calculated through the integration of the loss density over the whole coil. The proximity loss is through the calculation of the proximity field on each turn, and calculation of the proximity loss afterward. The input current linearly transitions from the top to bottom spiral over the whole length in each capacitor section, which is the same as in CSRC. Thus, skin-effect ESR of the i th turn is, if configured as a self- resonant structure If the ith turn is configured as a conventional structure as in a HSRC, the skin-effect ESR is 25 The total skin-effect ESR is In addition to the skin effect, the time-varying H-field around the coil traces causes eddy current loss in the copper foil. Since the H-field in the FSRC coil has an almost identical H-field compared to a conventional coil (as shown in Figure 9), the magnetic field distribution and the proximity related ESR are calculated using the same method as in a CSRC. H c is the H-field strength at the center point. H in is the H-field strength at the innermost point. H out is the outermost field. The H-field strength drop on each turn dH = H in − H out )/n. As has been shown previously: After obtaining the field distribution information, the proximity effect loss of i th turn is calculated using the standard formula for eddy- currents in a lamination where V ol i is the copper volume of the i th turn, where li,in and li,out are the inner and outer radius of i th turn, respectively. And B avg,i 2 is the average peak flux density square of the proximal H-field
The proximity effect ESR of ith turn is The total proximity-effect related ESR is R prox = The dielectric loss is calculated based on the loss tangent t g of the dielectric material Finally, the total equivalent series resistance (ESR) of the coil is Magnetic Shielding Effect The neighboring metal may destroy magnetic coupling and requires ferrite shielding, which impacts the receiver coil inductance and induced voltage. To facilitate the proposed self-resonant coil design, FEA simulation using Ansys Maxwell 2D is used to quantify the impact. The simulated geometry is shown in Figure 10, which includes the transmitter coil with a uniform magnetic field. Due to the uniform magnetic field, the coupling is constant if the receiver coil is placed on other positions on the transmitter surface, or if the transmitter coil is configured with other geometries as long as the field is uniform. The ferrite is a high frequency, low-loss material with a permeability of 120. The metal is a 2 oz copper layer representing a 2-layer PCB. The length of the coil is 17.8 cm (7 inch) and the maximum height is 1.02 mm (0.04 inch). In the simulation, the geometry of the coil and the thickness of ferrite are swept to evaluate the shielding effect of various ferrite thicknesses. The inner radius is swept from 3 cm to 6 cm. The number of turns is swept from 2 to 3. The width is designed for each geometry leaving a 2 mm gap between adjacent turns. The outer length is fixed at 8.9 cm (3.5 inch) based on the space available on the laptop. The inductance and induced voltage are evaluated and compared for two situations: 1) with ferrite only, and 2) with ferrite+copper. The results are shown in Figures 11A – 11B. In Figure 11A the inductance ratio is the inductance with ferrite only L f over the inductance of the coil without any shielding L0, or the inductance with ferrite and copper Lfcu over L0. In Figure 11B, the voltage ratio is the induced voltage with ferrite only V ind,f over the inductance of the coil without any shielding V ind , or the inductance with ferrite and copper V ind,fcu over V ind . Without the copper layer, the ferrite shielding enhances the magnetic field, thus increasing the coil inductance for all ferrite thicknesses. The ferrite also forms a low impedance loop that facilitates more magnetic flux penetrating the Rx coil, leading to an increased induced voltage. With the copper layer, part of the magnetic flux that penetrates through the ferrite causes eddy currents leading to a reduced inductance and induced voltage if the ferrite is thin. Increasing the ferrite thickness reduces the penetrating flux to the copper and thus increases inductance and induced voltage. A 1 mm ferrite is sufficient to reduce L fcu /L f to 5 % and yields a voltage ratio of 0.95, and the improvement becomes increasingly slow after this thickness. Considering this, a ferrite thickness of 1 mm is selected, which is also approaching the height limit of 1.02 mm. Both voltage and inductance ratios will be used in the systematic design. Coil Design The FSRC and HSRC coils developed in the prior sections are compared to conventional coil geometries in a target 6.78 MHz, 50 W receiver. For each of the self-resonant coils, Rogers RO3003 dielectric is used. The substrate is 0.13 mm thick and has D k = 3 and t g = .001. Wurth 364003 RF ferrite sheet is used for the magnetic shielding layer. In the internal stage design, geometric iteration is used to calculate coil circuit parameters under application geometric requirements. Four types of coils are compared 1) solid copper wire coil, 2) conventional self-resonant coil (CSRC), 3) HSRC, and 4) FSRC. The modeling of 2) was previously reported. Sweeping geometries within application requirement, the designed circuit parameters for the solid coil are shown in Figures 12A – 12B. Note that the thickness is constrained to 0.2 mm. Figure 12A shows the LCR parameters, where R is represented by Q for a better sense of the coil quality. The dashed curve indicates a 6.78 MHz LC resonance. One curve is the LC design that cancels reactance for a 50 W rectifier using B340LB diodes. The interested induced voltage area, which is also determined by the rectifier stage, is highlighted by the box. Figure 12B is the induced voltage when the coil is placed in 20 µT magnetic field. The design result for CSRC, HSRC, and FSRC are shown in Figures 13A – 13B, all resulting from geometric iteration. The x symbols in Figures 13A – 13B and Figures 12A – 12B are designs with 1.60 µH, 360 pF, and 36 V induced voltage, which meet the requirements of the target application. A set of coil schematic corresponding to the x symbols are shown in Figures 14A – 14D. With limited thickness, solid copper can only use thin wire and have limited conduction area, thus limiting the Q. CSRC configures the capacitors of every turn in parallel, requiring a limited capacitance from each turn, thus resulting in the thin width design. In comparison, HSRC and FSRC configure the capacitance of each turn (if any) in series, expanding the required capacitance of each turn, thus resulting in a wider traces than CSRC. Combining the four coils, the resulting LCR design space is shown in Figure 15A only showing the minimum ESR. The type of coil is shown in Figure 15B. Number 1 to 4 represents SC, CSRC, HSRC, and FSRC. The complete coil performance capabilities shown in Figure 15A are integrated into a multi-receiver system. The complete end-to-end system-level design result showing the power loss on every individual stage is shown in Figure 16, which follows a similar trend as found when thicker solid-core ferriteless receivers are used for nonmetal receivers. The optimal design is B0 = 21 µT and yields a power loss of 6.94 W when 100 W are transferred two receivers. Note that the fabricated transmitter is configured at B 0 = 20 µT and results in a close power loss of 6.99 W. The receiver will be optimized for B0 = 20 µT considering the tiny difference to the optimal point. The design result for the metal-body laptop receiver are: L s = 1.6 µH, C s = 360 pF, ESR = 0.18 Ω, and Vo = 31.5 V. The target Vo is 31.5 V. The receiver coil structure is selected to be FSRC, with lri=5.47 cm, lro = 8.89 cm, wr = 1.23 mm, and nr = 2. SIMLUATION AND EXPERIMENTAL VERIFICATION FEA Simulation Result The proposed coils are simulated using Ansys HFSS. The top view of the schematic in the simulation is shown in Figure 17. The bottom layer, viewed from the bottom, appears identical to the top layer due to the symmetric structure. The impedance curve of the FSRC coil is shown in Figure 18 directly imported from HFSS, showing series LC resonance. The y-axis is the impedance. The x-axis is the frequency range from 5.5 to 8.5 MHz. The simulated resonant frequency is 6.60 MHz (-0.5 %). Another simulation was done at 1 kHz, extracting the capacitance to be 378 pF(+5 %). From the simulated resonant frequency and capacitance, the inductance is calculated to be 1.54 µH(-3.8 %), illustrating the accuracy of the modeling. The FSRC coil alone, removing ferrite and copper, is also simulated. The results are summarized in Figure 20D, Table. I, showing high accuracy. The ESR measurement of FSRC with ferrite is not accurate, due to additional ferrite loss which is not modeled. In addition to the two-turn rectangular coil that maximize system efficiency, a four-turn circular-shaped geometry is studied for both FSRC and CSRC to compared their E-field. The coil schematic and calculated longitude potential are shown in Figure 19. Based on calculation, FSRC has a significant E-field strength reduction. FEA simulation results are shown in Figures 20A – 20C. FSRC has a significantly lower dielectric loss compared to CSRC, which indicates the E- field in the dielectric is reduced. Experimental Verification To verify the coil design, a FSRC is fabricated using Rogers 3003 low- loss PCB laminate, as shown in Figure 21A. The coil impedance parameters are measured using an Agilent 4294A impedance analyzer and compared with the modeled and simulated predictions. As shown in Figure 20D, Table I, the measurement results match well with the FEA simulation. Figure 21B presents the experimental setup, where the FSRC is implemented with the proposed rectifier and is tested with a 100 W 6.78 MHz wireless charging station as shown in Figure 21B. The FSRC implements one 50 W receiver used to power an aluminum-body laptop, while a solid-core coil with no ferrite is used for a second 50 W receiver used to power a plastic-body computer monitor. The system efficiency is defined as the total DC output power from all receivers divided by the transmitter side DC input power. Measured DC voltages and powers at the full load operating point are summarized in Figure 20E, Table II, together with a comparison to the model predictions. The measured power loss is 7.94 W compared to the calculation value of 6.99, proving the accuracy of the system modeling and design. The additional loss might be caused by ferrite. The ferrite typically has a loss tangent smaller than 2 %. However, no detailed modeling of how the power loss changes with B was provided to accurately quantify ferrite loss. Another possible reason is that the ferrite increases FSRC coil ESR, as shown in the simulation. The measured system efficiency is 92.7 %. The loss breakdown at this operating point is shown in Figure 22. CONCLUSION This document describes a self-resonant coil design for WPT charging of mobile electronics such as a laptop. The structure achieves a high-Q, low E-field, and thin profile. The design results are verified experimentally for the proposed FSRC. The systematic design of a multi-receiver system wirelessly charging both a laptop and computer monitor is detailed and a complete prototype of the FSRC is experimentally shown to achieve high efficiency. It will be understood that various details of the presently disclosed subject matter may be changed without departing from the scope of the presently disclosed subject matter. Furthermore, the foregoing description is for the purpose of illustration only, and not for the purpose of limitation. REFERENCES [1] J. Li, R. Qin, J. Sun, and D. Costinett, “Systematic design of a 100W 6.78-MHz wireless charging station covering multiple devices and a large charging area,” IEEE Transactions on Power Electronics, vol.37, no.4, pp.4877–4889, 2022. [2] N. S. Jeong and F. 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