FIELD OF THE INVENTION

The invention generally relates to wireless device chargers and more particularly to a wireless device charger having a cooling device to remove heat from the assembly.

BACKGROUND

Lithium-ion batteries used within today's personal devices have established limits to protect the device battery from being exposed to excessive temperatures. Guidelines for improving battery charging safety prescribe setting an upper-temperature threshold at 60° C. Typical charging temperatures range between -10° C. to +60° C.

Wireless power charging specification prescribes specification with received powers up to 60 watts (W), and have an arrangement for receivers to accept up to 15 W. The same benefits automotive battery chargers uses such that wireless fast charging can match plugged in the capability of a USB cable. Original equipment manufacturers (OEMs) of motor vehicles are now demanding this capability.

Various wireless chargers for mobile terminals are available in the market. A wireless charger generally outputs electrical energy of 5 W to a mobile terminal. In such a case, 80% up to 90% of the supplied electrical energy is converted into heat. This amount of heat does not affect the operation and charging of the mobile terminal, and thus, an additional heat processing apparatus is not required.

Further, mobile terminals provide various functions for communication with a vehicle. When used in a vehicle, a mobile terminal needs to keep charged while performing various functions. For this reason, it is necessary to charge the mobile terminal with a power greater than 5 W. In this case, large amount of heat will be generated during the charging is enough to affect the functions or charging of the mobile terminal. The higher temperature of the mobile or electronics device subsequently causes less charging efficiency or delay in charging, or at the worst may damage the electronics components.

Many wireless charging systems are available with different cooling strategies. Volumetric space for electronic components, such as a wireless device charger, is limited in an automotive environment. The charger is configured to move air within an enclosed space and/or move air from the heating, ventilation, and air conditioning (HVAC) duct through the charger and, more particularly, across the heat-generating components of the charger.

Existing structures are complex and efficiency is not up to expectation. The method of ingress protection against liquid and solid particles for the fan duct is not integrated. This can lead to damage to the fan integration system or adverse effects or no function. In some cases, water and some objects falling on the charger block the duct area. This, in turn, plugs the airflow and also poses risk to electrical and non-electrical components within the charger.

Therefore, for a wireless charger for a mobile terminal, there is a need for technology for efficiently managing heat generated during wireless charging. Moreover, the wireless charger is also needed to comply with industrial standards for protection against dust and water.

SUMMARY

This summary is provided to introduce a selection of concepts, in a simplified format, that are further described in the detailed description of the invention. This summary is neither intended to identify key or essential inventive concepts of the invention and nor is it intended for determining the scope of the invention.

The present disclosure relates to aspects of a wireless charger assembly for a mobile terminal. The wireless charger assembly has vents that supply to the bottom surface and edges of the user equipment while at the same time being resistant to any blockage from dust or water droplets.

In an embodiment, a wireless charging assembly is disclosed that has a housing with a first end and a second end. The wireless charging assembly includes a tray mounted to the first end and adapted to receive a user equipment. The tray includes a plurality of ribs on a top surface that are adapted to support the mobile terminal thereon. The tray also includes a plurality of openings on the top surface and are adapted to supply air to a surface of the user equipment facing the top surface and edges surrounding the surface of the user equipment. The tray also includes a plurality of channels formed on a bottom surface and in fluid communication with the plurality of opening to supply air to the plurality of openings. The wireless charging assembly includes an air supplying unit adapted to supply air to the plurality of channels. The wireless charging assembly also includes at least one coil mounted proximate to the bottom surface and adapted to provide wireless electrical energy.

The air supplying unit includes a cover plate attached to a second end of the housing and a fan installed at a fan opening in the cover plate and adapted to suck the air into the cover plate. In addition, the air supplying unit includes an air duct extending from a side of the cover plate and in fluid communication with the plurality of channels. Further, the air ducts supply the air from the fan to the plurality of the channels. The wireless charging assembly includes a mesh between a downstream end of the air duct and an upstream end of the plurality of channels to prevent the passage of dust and liquid droplets there through. The wireless charging assembly includes at least one opening in the air ducts.

According to the present disclosure, integration of the fan allows for constant airflow to the user equipment area so that the user equipment does not get hot during charging. Moreover, the mesh grill prevents blockage of the air-duct by the dust particles, and mitigate the risk posed to the fans due to the dust particles. Moreover, the mesh helps to restrict the entrance of objects/particles from the mat/tray side while allowing the subsequent air flow to the channels. Moreover, the openings in the air duct area add more air to the airflow from the fan while removing air from the air duct when back pressure is created to protect the fan from the backpressure.

To further clarify the advantages and features of the present invention, a more particular description of the invention will be rendered by reference to specific embodiments thereof, which is illustrated in the appended drawings. It is appreciated that these drawings depict only typical embodiments of the invention and are therefore not to be considered limiting of its scope. The invention will be described and explained with additional specificity and detail with the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

These and other features, aspects, and advantages of the present invention will become better understood when the following detailed description is read with reference to the accompanying drawings in which like characters represent like parts throughout the drawings, wherein:

Figure 1 illustrates an isometric view of a wireless charger assembly showing a first end to with a user equipment thereon, according to an embodiment of the present disclosure;
Figure 2 illustrates an isometric view of the wireless charger assembly showing a second end with an air supplying unit attached thereon, according to an embodiment of the present disclosure;
Figure 3 illustrates a cross section taken along lines 1-1 in Figure 1;
Figure 4 illustrates the direction of flow of air along the edges of the user equipment, according to an embodiment of the present disclosure;
Figure 5 illustrates an upside view of the cover plate, according to an embodiment of the present disclosure; and
Figure 6 illustrates an isometric view, a side view, and a cut section taken along lines 2-2 in Figure 5, according to an embodiment of the present disclosure; and
Figure 7 illustrates a mesh and the position thereof in the wireless charging assembly, according to an embodiment of the present disclosure.

Further, skilled artisans will appreciate that elements in the drawings are illustrated for simplicity and may not have been necessarily been drawn to scale. For example, the flow charts illustrate the method in terms of the most prominent steps involved to help to improve understanding of aspects of the present invention. Furthermore, in terms of the construction of the device, one or more components of the device may have been represented in the drawings by conventional symbols, and the drawings may show only those specific details that are pertinent to understanding the embodiments of the present invention so as not to obscure the drawings with details that will be readily apparent to those of ordinary skill in the art having benefit of the description herein.

DETAILED DESCRIPTION OF FIGURES

For the purpose of promoting an understanding of the principles of the invention, reference will now be made to the embodiment illustrated in the drawings and specific language will be used to describe the same. It will nevertheless be understood that no limitation of the scope of the invention is thereby intended, such alterations and further modifications in the illustrated system, and such further applications of the principles of the invention as illustrated therein being contemplated as would normally occur to one skilled in the art to which the invention relates. Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skilled in the art to which this invention belongs. The system, methods, and examples provided herein are illustrative only and not intended to be limiting. Embodiments of the present invention will be described below in detail with reference to the accompanying drawings.

The present subject matter at least facilitates air movement within an assembly of the charger such that the mobile device temperature remains below a threshold i.e. below battery shutdown temperatures. The present subject matter improves charging performance by removing or redistributing heat within a wireless device charger (WDC), thereby extending the amount of time for charging operation and providing a higher state of charge (SOC) over a shorter time period by eliminating charging interruption due to exceeding the temperature threshold.

Figures 1 to 3 shows various aspects of a wireless charging assembly 100, according to an embodiment of the present disclosure. Specifically, Figure 1 illustrates an isometric view of a wireless charger assembly 100 showing a first end 102A of a housing 102 to with a user equipment 104 thereon while Figure 2 illustrates an isometric view of the wireless charger assembly 100 showing a second end 102B of the housing 102 with an air supplying unit 106 attached thereon. Further, Figure 3 illustrates a cross-section taken along lines 1-1 in Figure 1.

The wireless charger assembly 100 may be installed inside an interior of a vehicle. In one example, the wireless charger assembly 100 may be installed at a central console of the vehicle, for instance, proximate to a gear shift knob of the vehicle. The wireless charger assembly 100 may be used to charge the user equipment 104, such as a mobile phone. The wireless charger assembly 100 also ensures that the user equipment 104 does not get overheated due to the charging. The wireless charger assembly 100 prevents overheating by supplying constant air from the air supplying unit 106. The wireless charger assembly 100 does not rely on the air supply from a Heating, Ventilation, and Air Conditioning (HVAC) unit in the vehicle but instead draws air from the interior and/or exterior of the vehicle to cool the user equipment 104. Such an arrangement makes easy integration of the wireless charger assembly 100 with the vehicle interior without making any changes to the HVAC unit.

The wireless charger assembly 100 may include, but is not limited to, a tray 108, one or more coil 110, a mounting plate 112, a driver unit 114, spacers 116, details of which will be explained in subsequent paragraphs.

In one example, the housing 102 may form a major portion of the wireless charger assembly 100. The housing 102 may be made of a plastic material that may be used to contain different components of the wireless charger assembly 100. The housing 102 may have the first end 102A and the second end 102B. The housing 102 may house at least one coil 110 that may provide wireless electrical energy to charge the user equipment 104. In one example, multiple small sized coils 110 may be installed uniformly across the first end 102A. Further, the coils 110 may be stacked on top of each other as shown in Figure 3 or in any other configuration as per the design and designated charging power output of the wireless charger assembly 100. Alternatively, the housing 102 may have a single large-sized coil 110 that may be installed in the housing 102. As shown in Figure 3, the mounting plate 112 may accommodate the coils 110 thereon to place the coils 110 proximate to the tray 108. Further, the mounting plate 112 may be supported in the housing using spacers 116. In one example, the driver unit 114 may provide electrical energy to power the coils 110. The driver unit 114 can be a printed circuit board (PCB) to power the coils 110.

As shown in Figures 1 and 3, the tray 108 may be mounted on the first end 102A of the housing 102. The tray 108 is configured to receive the user equipment 104 thereon and may hold the user equipment 104 during the charging. The tray 108 may have a top surface 108A and a bottom surface 108B. The top surface 108A may be configured to receive the user equipment 104 while the bottom surface 108B is opposite to the top surface 108A and may be proximate to at least one coil 110. The tray 108 may also include lips 108C on edges of the top surface 108A and may extend upward forming a cup to prevent slippage of the user equipment 104 from the tray 108 while charging. One of the lips 108C may include a cut out to allow lifting and placement of the user equipment 104 on the tray 108. The tray 108 may also include a plurality of ribs 108D that may protrude from the top surface 108A. The ribs 108D may extend in such a way the ribs 108D provides a platform to support the user equipment 104 thereon. Moreover, the ribs 108D holds the user equipment 104 at an elevated position to form a gap underneath the user equipment 104 to allow air to pass through. In one example, the ribs 108D can be formed of the same material as that other parts of the tray 108. Alternatively, the ribs 108D may be rubber inserts on a mat attached to the top surface 108A. In either case, the ribs 108D allows the formation of gaps for the passage of air therethrough.

In one example, the tray 108 may also include a plurality of openings 108E on the top surface 108A. The openings 108E may be configured to supply air to the user equipment 104 to remove heat generated by the user equipment 104 during charging of the user equipment 104. In one example, the openings 108E may be interposed between consecutive ribs 108D in the grid of the ribs 108D as shown in Figure 1. In one example, the openings 108E may supply air to a surface 104A of the user equipment 104 facing for cooling that surface 104A. In one example, the surface 104A may be the backside of the user equipment 104. In addition, the openings 108E may also supply air to cool the edges 104B of the user equipment 104.

Referring now to Figure 3 shows the cut section of the wireless charger assembly 100 and Figure 4 that shows the flow of air around the edges 104B. In the illustrated example, a set of openings 104B of the periphery of the grid may supply the air around the edges 104B of the user equipment 104 to remove the heat. Further the lips 108C may guide the air towards the edges 104B of the user equipment 104 to efficiently remove the heat. In one example, the air exiting from the corner most set of openings describes a flow path while making contact with the edges 104B of the user equipment 104 to remove the heat. Removal of heat from the user equipment 104 allows for lower temperature and avail higher charging efficiency. The tray 108 may also include a plurality of channels 108F formed on the bottom surface 108B of the tray 108. The channels 108F may be in fluid communication with the openings 108E and may supply air to the openings 108E.

As mentioned before, the air supplying unit 106 may provide air flow to cool the user equipment 104 while charging. Details of the air supplying unit 106 are now be provided with respect to Figures 5 and 6 in conjunction with Figures 2 and 3. Specifically, Figure 5 illustrates an upside view of the cover plate and Figure 6 illustrates an isometric view, a side view, and a cut section taken along lines 2-2 in Figure 6. The air supplying unit 106 may be formed as a detachable component to the housing 102. A detachable air supplying unit 106 allows for easy replacement of the air supplying unit 106 or the housing 102 in case of fault or failure of any component of the wireless charging assembly 100. Alternatively, the air supplying unit 106 may be formed as an integrated unit to the housing 102. The air supplying unit 106 may include but is not limited, to a cover plate 118, a fan 120, and an air duct 122.

In one example, the cover plate 118 may form a major section of the air supplying unit 106. The cover plate 118 may be mounted on the second end 102B of the housing 102 as shown in Figure 3. The cover plate 118 may include different sections. In one example, the cover plate 118 may include a fan section 118A that may house the fan 120. The fan section 118A may include a fan opening 118B, such that the fan 120 may be installed at the fan opening 118B. The fan opening 118B may have three portions that correspond to the number of blades on the fan 120 as shown in Figure 5. The fan 120 may be configured to suck the air into the cover plate 118. In one example, the driver unit 114 may provide electrical energy to power the fan 120. Further, the fan 120 may spin at a constant speed to generate a constant airflow rate. Alternatively, the fan 120 may be capable of spinning at variable speed to generate an airflow of variable flow rate. As shown in Figure 3, the fan 120 is installed opposite the tray 108 so that the fan 120 does not obstruct or limit the space available to place the user equipment 104. Such an arrangement allows for larger sized user equipment 104 to be used for charging while keeping the wireless charger assembly 100 compact.

The cover plate 118 may also include a supply section 118C that is downstream to the fan section 118A. The supply section 118C may include a plurality of supply ducts 124 to supply the air from the fan 120 to the air ducts 122. The supply section 118C may be inclined as shown part B of Figure 6. The supply section 118C is inclined to enable the supply ducts 124 to guide air from the fan 120 to the air ducts 122.

In one example, the air duct 122 may be installed downstream to the supply duct 124. When installed, the air duct 122 may be attached to a wall of the housing 102, such that the air duct 122 may be supply air along the side of the housing 102. As shown in Figure 3, the air ducts 122 and the walls 102C of the housing 102 formes a close section for the air to flow to the tray 108. In one example, the air ducts 122 may be enclosed creating a path without the walls 102C of the housing 108. The air ducts 122 may include an upstream end 122A and a downstream end 118B. As shown in Figure 5, the upstream end 122A is attached to the supply section 118C. On the other hand, the downstream end 122B may be attached to the tray 108 as shown in Figure 2. In one example, the downstream end 122B may be covered by a cover section 108G extending along a portion of the length of the air duct 122. In another example, the downstream end 122B may completely be covered by the cover section 108G. the air duct 122 may include a plurality of flow guides 122C extending through the length of the air duct 122. The flow guides 122C forms a separate air stream for each channel 108F.

In one example, the air duct 122 may include a plurality of bleed holes 126. The bleed holes 126 may be configured to perform two tasks. First, the bleed holes 126 allows the ingress of additional air into the air duct 122 as shown in cut section 1-1 in Figure 3 and cut section 2-2 in Figure 6. The ingress of additional air occurs due to vacuum created by the air flowing towards the tray 108. The second task of the bleed holes 126 is to allow air to escape from the air duct 122 when back pressure is created to release the backpressure. Allowing the air to escape during back pressure prevent damage to the fan 120 that otherwise would have occurred in case the back pressure is not released.

According to the present disclosure, the air supplying unit 106 supplies the air at a predetermined flow rate and the tray 108 homogenously distributes the air underneath and around the sides of0020the user equipment 104. However, during the operation of the wireless charger assembly 100, foreign objects, such as dust particles may enter the openings 108E and clog the channels 108F and/or the air duct 122. In one order to prevent such clogging, the wireless charger assembly 100 may include mesh details of which are provided with respect to Figure 7 hereinafter.

Specifically, Figure 7 illustrates a mesh 128 and the position thereof in the wireless charging assembly 100. As shown in parts (A) and (B) of Figure 7, the first end 102A of the housing 102 may include a cut-out section 102D to allow mounting of the mesh inside the cut-out section 102D. In one example, the cut-out section 102D may be formed in such a way that the mesh 128 is installed between the downstream end 122B of the air duct 122 and an upstream end of the channel 108F. As a result, the mesh 128 prevents the passage of dust particles 702 in the channels 108F from entering the air duct 122. On the other hand, the mesh 128 may be configured to allow liquid droplets 704 to pass therethrough, so that the liquid droplets 704 may exit the cover plate either via the bleed holes 126 or via the fan opening 118B as shown in cut section 3-3 in Figure 7. In either case, the liquid droplets 704 is prevented to accumulate in the cover plate and the dust particle 702 is prevented from entering the air duct 122. In one example, the mesh 128 can be a structured mesh that has an IP4X rating.

Referring now to Figure 3 to explain the operation of the wireless charger assembly 100. Initially, the user equipment 104 may be placed in the tray 108 and the charging may be initiated. The charging may either be initiated by switching ON the coil 110 or the coil 110 may remain activated as soon as the ignition key is inserted. When the charging starts, the PCB may switch ON the fan 120 and the fan 120 sucks in the fresh air from the environment. Further, the air is guided from the supply ducts 126 and through the air duct 122 which carry air from the fan to the channels 108F. The air flow in a longitudinal direction in the tray 108. The channels 108F present below the openings 108E release the air underneath the user equipment 104. Further, the ribs 108D are provided on Mat which allows a gap between mobile and top surface 108A for the air to escape into the environment from user equipment 104. Holes or perforations on the mat align with the air duct channels which facilitate the air flow from openings 108E to the back surface 104A and edges 104B of the user equipment 104. The openings 108E and the channels 108F provide the distribution of airflow to the complete area where the use equipment 104 is placed.

The present subject matter refers a simple structured/Design and smooth air flow, extra air flow. Further, a provision for air exit is provided when back pressure is created. The mesh cover integration is rendered for restriction of solid particles.

While specific language has been used to describe the present disclosure, any limitations arising on account thereto, are not intended. As would be apparent to a person in the art, various working modifications may be made to the method in order to implement the inventive concept as taught herein. The drawings and the foregoing description give examples of embodiments. Those skilled in the art will appreciate that one or more of the described elements may well be combined into a single functional element. Alternatively, certain elements may be split into multiple functional elements. Elements from one embodiment may be added to another embodiment. ,CLAIMS:1. A wireless charging assembly (100) comprising:
a housing (102);
a tray (110) mounted on a first end (102A) the housing (102) and adapted to receive a user equipment (104), the tray (110) comprising;
a plurality of ribs (108D) protruding from a top surface (108A) to support the user equipment (104) thereon;
a plurality of openings (108E) on the top surface (108A) adapted to provide ambient air on a surface of the user equipment (104) facing the top surface (108A) and on surrounding edges; and
a plurality of channels (108F) formed on a bottom surface and in fluid communication with the plurality of openings (108E) to supply air to the plurality of openings (108E);
an air supplying unit mounted on the housing (102) adapted to supply air to the plurality of channels (108F); and
at least one coil (110) installed inside the housing (102) and proximate to the bottom surface and adapted to provide wireless electrical energy.

2. The wireless charging assembly (100) as claimed to the claim 1, wherein a first set of openings (108E) from among the plurality of openings (108E), is adapted to supply the ambient air to the surrounding edges, wherein the first set of openings (108E) is formed proximate to the corners of the tray (110).

3. The wireless charging assembly (100) according to the claim 1, wherein the air supplying unit comprising:
a cover plate (118) attached to a second end (102B) of the housing (102);
a fan (120) installed at a fan (120) opening in the cover plate (118) and adapted to suck the air into the cover plate (118); and
an air duct (122) extending from a side of the cover plate (118) and in fluid communication with the plurality of channels (108F), wherein the air duct (122) supplies the air from the fan (120) to the plurality of the channels (108F).

4. The wireless charging assembly (100) according to the claim 1, comprising a mounting plate (112) to accommodate at least one coil (110) proximate to the tray (110).

5. The wireless charging assembly (100) according to the claim 1, comprising a driver unit (114) to provide power to one of the fan (120) and the at least one coil (110).

6. The wireless charging assembly (100) according to the claim 3, wherein the air duct (122) includes a plurality of flow guides along the length of the air duct (122).

7. The wireless charging assembly (100) according to the claim 3, wherein the cover plate (118) comprising a plurality of supply ducts to supply air from the fan (120) to the air duct (122).

8. The wireless charging assembly (100) according to the claim 3, comprising mesh (128) between a downstream end of the airduct and an upstream end of the plurality of channels (108F) to prevent passage of dust therethrough.

9. The wireless charging assembly (100) according to the claim 6, whererin the air duct (122) includes at least one opening to allow ingress of additional air into the air duct (122).

10. The wireless charging assembly (100) according to the claim 4, comprising spacers (116) to support the mounting plate on the housing (102).