Abstract
2D coil design limits the use of wireless power transfer (WPT) in many products with freeform outer shapes. In this paper, enabled by 3D printed electronics, we propose a systematic approach to design and fabricate 3D coils for WPT. Based on the circular spiral and rectangular spiral patterns, 3D receiver and transmitter coils can be generated on an arbitrarily selected region of a product and its offset, respectively. Mathematical models are proposed to estimate the self-inductance and the mutual-inductance of the 3D arbitrarily shaped coils for 3D WPT. This leads to a new design approach of a 3D WPT system. Several sets of 3D printed WPT systems were designed, simulated, and prototyped to demonstrate the effectiveness of the proposed design approach as well as the mathematical models. The calculation speed of the proposed mathematical models is 30 times faster than the simulation, and compared with the measurement results, the calculation results have mean absolute errors of 2.63% and 4.45% regarding the self- and the mutual-inductance, where the simulation results have mean absolute errors of 1.20% and 2.38%, respectively. Measurements also indicate that with a 5V input, the prototypes are able to deliver 1-watt power at an efficiency ranging between 20.9% and 25.3%. It was concluded that the proposed approach is feasible and promising for designing and manufacturing WPT using 3D printed electronics.
Highlights
Wireless power transfer (WPT), known as wireless charging, attracted a wide range of attention in the past decade, mainly due to the rapid development of mobile technology and electrical vehicles [1]
We developed new mathematical models, which are extensions of current work, for calculating the self- and mutual- inductance of an arbitrarily shaped 3D coil(s); both the design approach and the models were verified by simulations and experiments, where prototypes were manufactured using 3D printed electronics
APPLICATIONS OF 3D PRINTED ELECTRONICS IN wireless power transfer (WPT) Though the conductivity of silver inks is less than copper wires, the low fabrication cost and the ability of using flexible substrates attracted the attention of researchers and industry. 2D Printed electronics, i.e. single layer silver ink printing on various substrates, was introduced for designing lowpower WPT systems earlier than for 3D designs
Summary
Wireless power transfer (WPT), known as wireless charging, attracted a wide range of attention in the past decade, mainly due to the rapid development of mobile technology and electrical vehicles [1]. Recent developments of (consumer) product design introduces more 3D (freeform) outer shapes [4], as the visual appearance and usability play fundamental roles in the final decision of a customer when seeking congruency between price and functionality This is especially true for personalized designs, where besides the form factors, rapid and accurate response to customers’ demands is another key. We propose a systematic approach for designing 3D transmitter and receiver coils that can be fabricated by 3D printed electronics, enabling a more effective and efficient IPT for freeform designs. We developed new mathematical models, which are extensions of current work, for calculating the self- and mutual- inductance of an arbitrarily shaped 3D coil(s); both the design approach and the models were verified by simulations and experiments, where prototypes were manufactured using 3D printed electronics.
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