Magnetically permeable structures
View Patent ↗An apparatus, a system and a method for wireless power transfer are disclosed. A method of forming a physical core of a wireless power transfer device includes positioning two or more electromagnetically permeable members adjacent to one another and applying longitudinal pressure to an end of the electromagnetically permeable members, the electromagnetically permeable members at least partially encapsulated in retaining compound. A wireless power transfer device includes a casing in which is housed an induction coil, a plurality of electromagnetically permeable members arranged in a line and a retaining compound.
1. A wireless power transfer device, comprising:
a casing in which is housed:
an induction coil;
a plurality of electromagnetically permeable members, two or more of the electromagnetically permeable members abutting one another; and
a retaining compound at least partially encapsulating the electromagnetically permeable members, wherein the retaining compound maintains an applied longitudinal pressure between adjacent electromagnetically permeable members.
2. The wireless power transfer device of claim 1 , wherein the electromagnetically permeable members are arranged in a plurality of substantially parallel lines.
3. The wireless power transfer device of claim 2 , wherein the spacing between adjacent parallel lines is configured to allow a substantial portion of the electromagnetic field produced by the induction coil to pass through the parallel lines of electromagnetically permeable members.
4. The wireless power transfer device of claim 1 , wherein the electromagnetically permeable members include ferrite bars.
5. The wireless power transfer device of claim 1 , wherein the electromagnetically permeable members and induction coil are housed within the casing.
6. The wireless power transfer device of claim 1 , wherein the applied pressure reduces air gaps between the two or more of the electromagnetically permeable members abutting one another when positioned end to end to form a bar or positioned in a grid.
7. The wireless power transfer device of claim 1 , wherein the applied pressure ensures tight coupling between the two or more of the electromagnetically permeable members abutting one another.
8. The wireless power transfer device of claim 7 , wherein the tight coupling results in a permeability of the two or more of the electromagnetically permeable members abutting one another being substantially similar to a permeability of a single electromagnetically permeable member.
9. The wireless power transfer device of claim 1 , wherein the retaining compound is further configured to maintain a position of the plurality of electromagnetically permeable members.
10. The wireless power transfer device of claim 1 , wherein the retaining compound is further configured to maintain a spacing of and an orientation of the induction coil.