Wireless power supply system and multi-layer shim assembly
A wireless power supply includes a multi-layer shim assembly. Each shim aids in alignment of coils and routing of conductors in a multi-layer coil array. A shield or PCB can be used as part of the multi-layer shim assembly. Wires can be routed through channels to the edge of the shim assembly or wires can protrude through a portion of the multi-layer shim assembly. Traces can be used to route current through the multi-layer shim assembly. Plastic shims can be created by over-molding coils with plastic.
1. A multi-layer shim assembly for use in positioning an upper plurality of wireless power coils and a lower plurality of wireless power coils in a multi-layer coil array, said multi-layer shim assembly comprising:
a first shim layer including a first guide portion for aligning said upper plurality of wireless power coils in said multi-layer coil array and a first routing portion for routing electrical connections from each of said upper plurality of wireless power coils, wherein said first shim layer includes a major surface, and wherein said first guide portion includes a first wall portion extending from said major surface to define a first recess to simultaneously encompass said upper plurality of wireless power coils therein, said first wall portion encompassing said upper plurality including at least two wireless power coils; and
a second shim layer joined with said first shim layer, said second shim layer including a second guide portion for aligning said lower plurality of wireless power coils in said multi-layer coil array and a second routing portion for routing electrical connections from each of said lower plurality of wireless power coils, wherein said second shim layer includes a major surface, and wherein said second guide portion includes a second wall portion extending from said major surface to define a second recess to simultaneously encompass said lower plurality of wireless power coils therein, said second wall portion encompassing said lower plurality including at least two wireless power coils,
wherein said first guide portion and said second guide portion cooperate to align said plurality of wireless power coils in a predefined, overlapping, coil array, wherein said first recess is offset with respect to said second recess such that said upper plurality of wireless power coils is substantially axially offset with respect to said lower plurality of wireless power coils when received within said first and second recesses, respectively.
2. The multi-layer shim assembly of claim 1 wherein said first shim layer is constructed from a non-conductive material.
3. The multi-layer shim assembly of claim 1 wherein said first shim layer is at least partially constructed from a flux concentrating material, wherein said flux concentrating material increases inductance of said upper plurality of wireless power coils and enhances a flux path within said multi-layer shim assembly.
4. The multi-layer shim assembly of claim 1 wherein said first shim layer is at least partially constructed from a shielding material, wherein said first guide portion includes at least one of a bump, post, peg, and extrusion constructed from a flux concentrating material.
5. The multi-layer shim assembly of claim 1 wherein said first shim layer is a printed circuit board.
6. The multi-layer shim assembly of claim 1 wherein said first routing portion and said second routing portion include a channel system for routing wires between said upper and lower plurality of wireless power coils and an edge of said first and second shim layers, respectively.
7. The multi-layer shim assembly of claim 1 wherein at least one of said first routing portion and said second routing portion includes a stamped trace for routing power between an edge of said multi-layer shim assembly and a plurality of connection points for said upper and lower plurality of wireless power coils.
8. The multi-layer shim assembly of claim 7 wherein said stamped trace is over molded into at least one of said first shim layer and said second shim layer.
9. The multi-layer shim assembly of claim 1 wherein leads from each of said upper plurality of wireless power coils are routed along a surface of said first shim layer for connection to wireless power circuitry.
10. The multi-layer shim assembly of claim 9 wherein said leads from each of said upper plurality of wireless power coils are routed around a shield for connection to a printed circuit board.
11. The multi-layer shim assembly of claim 9 wherein leads from each of said upper and lower plurality of wireless power coils are routed to a connector, said connector capable of electrically connecting said upper and lower plurality of wireless power coils to wireless power circuitry.
12. A multi-layer shim assembly for use in positioning a first and second plurality of wireless power coils in a multi-layer coil array, said multi-layer shim assembly comprising:
a first shim layer including a major surface, a first guide portion for aligning said first plurality of wireless power coils in said multi-layer coil array, and a first routing portion for routing electrical connections from each of said first plurality of wireless power coils, wherein said first guide portion and said first routing portion each include a wall portion extending from said upper surface to define a recess in said first shim layer to simultaneously encompass said first plurality of wireless power coils and said electrical connections, respectively; and
a printed circuit board forming a second shim layer including said second plurality of wireless power coils in said multi-layer coil array printed on said printed circuit board and a second routing portion including a printed circuit board trace network,
wherein said first guide portion aligns said first plurality of wireless power coils in a predefined, overlapping, array with respect to said second plurality of wireless power coils such that said first plurality of wireless power coils is substantially axially offset with respect to said second plurality of wireless power coils.
13. The multi-layer shim assembly of claim 12 wherein at least a portion of said first shim layer is constructed from a flux concentrating material.
14. The multi-layer shim assembly of claim 12 wherein said first routing portion includes a channel system for routing wires between said first plurality of wireless power coils and said printed circuit board.
15. The multi-layer shim assembly of claim 12 wherein said first routing portion includes a stamped trace for routing power between said first plurality of wireless power coils and said printed circuit board.
16. The multi-layer shim assembly of claim 15 wherein said stamped trace is over molded into said first shim layer.
17. The multi-layer shim assembly of claim 9 wherein said printed circuit board trace network provides an electrical connection between said second plurality of wireless power coils and a plurality of connection points for wireless power circuitry and said printed circuit board trace network provides an electrical connection between said first routing portion and said plurality of connection points for wireless power circuitry.
18. A multi-layer shim assembly comprising:
an upper shim layer including a first recess that is shaped to simultaneously receive each of a first plurality of wireless power coils therein, the upper shim layer including a first plurality of traces to extend from each of the first plurality wireless power coils;
a middle shim layer including a second recess that is shaped to simultaneously receive each of a second plurality of wireless power coils therein, the middle shim layer including a second plurality of traces to extend from each of the second plurality of wireless power coils,
a lower shim layer including a third recess that is shaped to simultaneously receive each of a third plurality of wireless power coils therein, the lower shim layer including a third plurality of traces to extend from each of the third plurality of wireless power coils,
wherein the first, second and third recesses are axially offset with respect to each other to align the first, second and third plurality of wireless power coils in a predefined partially overlapping three-dimensional coil array when the first, second and third plurality of wireless power coils are received within their respective recesses.
19. The multi-layer shim assembly of claim 18 wherein one of the upper shim layer, the middle shim layer, and the lower shim layer includes a lateral extension that protrudes beyond the others of the upper shim layer, the middle shim layer, and the lower shim layer.
20. The multi-layer shim assembly of claim 18 wherein a portion of the outer periphery of the upper shim layer, the middle shim layer, and the lower shim layer are in substantial vertical alignment with respect to each other.
21. The multi-layer shim assembly of claim 18 further including a shield adjacent at least one of the upper shim layer, the middle shim layer, and the lower shim layer.