Wireless charging coil assembly

Abstract

A wireless charging coil assembly comprises a coil which is of a double-wire parallel winding single-layer structure and is formed by winding two copper enameled wires; and the nanocrystalline flexible magnetic isolation sheet is of a sheet-shaped structure, and the coil is arranged on the nanocrystalline flexible magnetic isolation sheet. The wireless charging coil assembly is reasonable in design, the coil is of a double-wire parallel winding single-layer structure, the thickness of the coil is reduced by about 50%, the magnetic isolation sheet is made of flexible nanocrystalline soft magnetic materials, meanwhile, the coil is arranged in an arc shape, the curved surface fitting degree is improved to more than 95%, the magnetic shielding effectiveness is improved by 3-5 dB, and the application prospect is wide.

Description

Technical Field

[0001] This utility model relates to the field of wireless charging technology, and specifically to a wireless charging coil assembly. Background Technology

[0002] With the widespread application of wireless charging technology in the consumer electronics field, small electronic devices such as earphone charging cases have placed higher demands on the thinness, space adaptability, and charging efficiency of wireless charging modules.

[0003] Traditional wireless charging coil components typically employ a single-wire, multi-layer winding structure to improve coupling efficiency. However, this multi-layer stacking design significantly increases coil thickness, limiting the flexibility of the internal space layout of the charging case.

[0004] In addition, conventional magnetic shielding materials (such as ferrite) are limited by their brittle and rigid characteristics, making it difficult to fit the complex curved structure inside the charging box. This leads to magnetic flux leakage and increased eddy current loss, which in turn affects charging efficiency and causes local overheating problems.

[0005] In existing technologies, some solutions to address the coil thickness issue involve reducing the wire diameter or optimizing the winding density, but these methods can easily lead to increased resistance and temperature rise. Improvements to the adhesion of magnetic shielding materials are often achieved through segmented splicing, which still presents problems such as complex processes and discontinuous magnetic circuits.

[0006] Therefore, there is an urgent need to develop a new type of wireless charging coil assembly that can ensure efficient energy transmission while also possessing an ultra-thin shape and adaptability to curved surfaces. Utility Model Content

[0007] Purpose of the utility model: In order to overcome the above shortcomings, the purpose of this utility model is to provide a wireless charging coil assembly with a reasonable design. Through the synergistic application of the double copper wire parallel winding single-layer structure design and flexible nanocrystalline magnetic shielding material, it solves the problems of coil thickness and charging efficiency, insufficient adaptability of magnetic shielding material to complex contours, limited thermal management performance, and low space utilization in the existing wireless charging coil assemblies. It has broad application prospects.

[0008] Technical solution: A wireless charging coil assembly, comprising:

[0009] The coil is a double-wire parallel-wound single-layer structure, made of two copper enameled wires wound together;

[0010] A nanocrystalline flexible magnetic shielding sheet, wherein the nanocrystalline flexible magnetic shielding sheet has a sheet-like structure and the coil is disposed on the nanocrystalline flexible magnetic shielding sheet.

[0011] The following technical problems exist in existing wireless charging coil assemblies:

[0012] 1. The contradiction between coil thickness and charging efficiency: Although the traditional multi-layer winding structure can improve coupling efficiency, it leads to an increase in the overall thickness of the coil assembly, which cannot meet the urgent need for ultra-thin design of small electronic devices (such as earphone charging cases).

[0013] 2. Insufficient compatibility of magnetic shielding materials with complex contours: Traditional rigid magnetic shielding materials such as ferrites are difficult to fit into the irregular curved surfaces inside the charging box, resulting in uneven magnetic flux distribution, serious magnetic leakage, and reduced energy transmission efficiency.

[0014] 3. Limited thermal management performance: Non-tightly bonded magnetic shielding materials are prone to local magnetic saturation and eddy current losses, resulting in abnormal temperature rise and affecting charging safety and equipment lifespan;

[0015] 4. Low space utilization: The volume occupied by the rigid magnetic shielding sheet limits the expansion of battery capacity and the optimization of the layout of other functional modules inside the charging box.

[0016] Therefore, this utility model provides a novel wireless charging coil assembly, which achieves the following objectives through the synergistic application of a double copper wire parallel-wound single-layer structure design for the coil and a flexible nanocrystalline magnetic shielding material for the magnetic shielding sheet:

[0017] 1. In the single-layer winding mode, the effective magnetic cross-sectional area is increased by using a dual-line parallel layout, breaking through the thickness limitation of traditional single-line multi-layer structures;

[0018] 2. The high permeability and low coercivity of nanocrystalline materials enhance the magnetic field focusing ability, and their flexible characteristics enable full fit with the shell contour, reducing magnetic flux leakage.

[0019] 3. By optimizing the coil winding method (winding two copper enameled wires together on a single plane to form a phase-complementary arrangement), the proximity effect loss is reduced. Combined with the high-frequency and low-loss characteristics of nanocrystalline materials, the temperature rise is significantly suppressed.

[0020] 4. The ultra-thin integrated structure described above can free up internal space in the charging case, creating layout conditions for increasing battery capacity and integrating additional functional modules such as sensors.

[0021] Furthermore, in the aforementioned wireless charging coil assembly, the diameter of the copper enameled wire is 0.2mm.

[0022] Furthermore, in the aforementioned wireless charging coil assembly, the coil is arranged in an arc shape.

[0023] The coil in the wireless charging coil assembly is arranged in an arc shape, which is a continuous and smooth curve. Its radius of curvature is precisely designed according to the specific requirements of the internal space or external contour of the adapted electronic device to achieve a high degree of fit with the corresponding structure.

[0024] For example, when applied to an earphone charging case, the radius of curvature of the coil is set according to the arc-shaped space inside the charging case, so that the coil can fit tightly against the inner wall of the charging case, making effective use of space.

[0025] When the coil is set in an arc shape, the surface fit can be increased to over 95%, and the magnetic shielding efficiency can be improved by 3-5dB.

[0026] Furthermore, in the aforementioned wireless charging coil assembly, the material of the nanocrystalline flexible magnetic shielding sheet is nanocrystalline material after magnetic fragmentation.

[0027] The nanocrystals after being broken down into magnetic fragments are die-cut into flexible nanocrystal magnetic shielding sheets. At this point, the nanocrystals are flexible and their curvature can be changed at will, resulting in better fit.

[0028] Furthermore, the aforementioned wireless charging coil assembly also includes:

[0029] The fixture is used to attach the coil to the nanocrystalline flexible magnetic shielding sheet.

[0030] Furthermore, in the aforementioned wireless charging coil assembly, the surface of the fixture is provided with grooves for placing and fixing the coil and the nanocrystalline flexible magnetic shielding sheet.

[0031] The beneficial effects of this utility model are as follows: The wireless charging coil assembly described in this utility model is reasonably designed. The coil adopts a single-layer structure design with two copper wires wound in parallel. In the single-layer winding mode, the parallel layout of the two wires effectively increases the magnetic cross-sectional area. Compared with the traditional single-wire multi-layer structure, this design breaks through the thickness limitation, making the coil assembly lighter and thinner, and also reducing proximity effect loss. Combined with the high-frequency and low-loss characteristics of nanocrystalline materials, it significantly suppresses temperature rise. Utilizing the high permeability and low coercivity characteristics of nanocrystalline materials, the magnetic field focusing ability can be enhanced. The flexible characteristics of nanocrystalline materials can achieve full fit with the shell contour. Whether it is the irregular curved surface inside the charging box or other complex structures, the flexible nanocrystalline magnetic shielding material can fit tightly, thereby reducing magnetic flux leakage and improving energy transmission efficiency. Due to the reduction in coil assembly thickness and the optimization of magnetic shielding material, more space inside the charging box can be used for other purposes, which creates conditions for increasing battery capacity and has broad application prospects. Attached Figure Description

[0032] Figure 1 This is a coil surface view of the wireless charging coil assembly described in this utility model;

[0033] Figure 2 This is a schematic diagram of the nanocrystalline flexible magnetic shielding sheet of the wireless charging coil assembly described in this utility model.

[0034] Figure 3This is a schematic diagram of the cross-section of the coil and the nanocrystalline flexible magnetic shielding sheet of the wireless charging coil assembly described in this utility model.

[0035] Figure 4 This is a front view of the overall appearance of the wireless charging coil assembly described in this utility model;

[0036] Figure 5 This is a side view of the overall appearance of the wireless charging coil assembly described in this utility model;

[0037] Figure 6 This is a rear view of the overall appearance of the wireless charging coil assembly described in this utility model;

[0038] In the diagram: coil 1, copper enameled wire 11, nanocrystalline flexible magnetic shielding sheet 2, fixture 3, groove 31. Detailed Implementation

[0039] The following is in conjunction with the appendix Figure 1 , 2 Examples 1, 2, 3, 4, 5, 6 and Examples 1 and 2 further illustrate this utility model.

[0040] Example 1

[0041] like Figure 1 , 2 As shown in Figures 1 and 3, the wireless charging coil assembly of this utility model includes a coil 1 and a nanocrystalline flexible magnetic shielding sheet 2, wherein the coil 1 is disposed on the nanocrystalline flexible magnetic shielding sheet 2.

[0042] The manufacturing process of the wireless charging coil assembly described in this utility model is as follows:

[0043] 1. Take two 0.2mm copper enameled wires 11, place them side by side, and wind them together on a winding machine. During winding, the two copper enameled wires 11 are wound on the same plane according to the predetermined number of turns and shape.

[0044] Employing a single-layer structure design with double copper enameled wires wound in parallel, the parallel arrangement of the two wires effectively increases the magnetic cross-sectional area in the single-layer winding mode. Compared with traditional single-wire multi-layer structures, this design overcomes the thickness limitation, making coil 1 thinner and lighter.

[0045] The winding method of coil 1 described above employs a phase-complementary arrangement, enabling the wireless charging coil assembly to reduce proximity effect losses. The proximity effect refers to the uneven current distribution in multiple parallel wires due to the interaction of magnetic fields generated by the current, thus increasing resistance and energy loss. The phase-complementary arrangement ensures that the currents in adjacent wires are out of phase, thereby canceling out some of the magnetic field interaction and reducing proximity effect losses. Combined with the high-frequency, low-loss characteristics of nanocrystalline materials, temperature rise can be significantly suppressed. During high-frequency charging, nanocrystalline materials maintain low energy loss, reducing heat generation and improving charging safety and device stability.

[0046] 2. After the planar coil 1 is wound, it is processed to conform to the arc shape using a tooling. The shape of the tooling matches the final required arc of coil 1. The planar coil 1 is placed on the tooling, and the shape of the tooling is used to apply a certain pressure and temperature to the coil 1, so that the coil 1 gradually forms a curved shape.

[0047] The advantage of doing this is that it allows for the production of a thinner, curved coil 1, which can better fit the irregular curved surfaces inside small electronic devices, increasing the surface fit to over 95% and improving the magnetic shielding efficiency by 3-5dB.

[0048] 3. The nanocrystalline material is subjected to a magnetic fragmentation process to transform it into a smaller grain structure. The purpose of magnetic fragmentation is to alter the physical properties of the nanocrystals, giving them better flexibility and magnetic properties. The fragmented nanocrystalline material is then die-cut into the required shape and size of the nanocrystalline flexible magnetic shielding sheet 2. Because the nanocrystalline flexible magnetic shielding sheet 2 is now flexible, its curvature can be freely adjusted according to different application requirements, thus achieving better fit with various complex contours.

[0049] By utilizing the high magnetic permeability and low coercivity of nanocrystalline materials, the wireless charging coil assembly can enhance the magnetic field focusing capability. Flexible nanocrystalline magnetic shielding materials achieve a tight fit, reducing magnetic flux leakage and improving energy transfer efficiency.

[0050] The wireless charging coil assembly described in this invention mainly utilizes the principle of electromagnetic induction to achieve energy transmission through intermittent energy coupling of coil 1. When an alternating current passes through the transmitting coil, an alternating magnetic field is generated. The receiving coil is situated within this alternating magnetic field, and according to the law of electromagnetic induction, an induced electromotive force is generated in the receiving coil, thereby producing a current to charge the electronic device.

[0051] Example 2

[0052] Based on the structural foundation of Embodiment 1 and above, such as Figure 1 , 2 As shown in 3, 4, 5, and 6.

[0053] The wireless charging coil assembly of this utility model comprises a coil 1 bonded to a nanocrystalline flexible magnetic shielding sheet 2 via a fixture 3. The fixture 3 serves to position and fix the coil 1 and the nanocrystalline flexible magnetic shielding sheet 2, and its surface is provided with grooves 31 for placing and fixing the coil 1 and the nanocrystalline flexible magnetic shielding sheet 2.

[0054] In summary, the wireless charging coil assembly described in this utility model solves the problems of coil thickness versus charging efficiency, insufficient compatibility of magnetic shielding materials with complex contours, limited thermal management performance, and low space utilization in existing wireless charging coil assemblies by using a double copper wire parallel winding single-layer structure design and the synergistic application of flexible nanocrystalline magnetic shielding materials.

[0055] The above description is only a preferred embodiment of the present utility model. It should be noted that for those skilled in the art, several improvements can be made without departing from the principle of the present utility model, and these improvements should also be considered within the protection scope of the present utility model.

Claims

1. A wireless charging coil assembly, characterized in that, include: The coil (1) is a double-wire parallel-wound single-layer structure, made of two copper enameled wires (11); The nanocrystalline flexible magnetic shielding sheet (2) has a sheet-like structure, and the coil (1) is disposed on the nanocrystalline flexible magnetic shielding sheet (2).

2. The wireless charging coil assembly according to claim 1, characterized in that, The diameter of the copper enameled wire (11) is 0.2 mm.

3. The wireless charging coil assembly according to claim 1, characterized in that, The coil (1) is arranged in an arc shape.

4. The wireless charging coil assembly according to claim 1, characterized in that, The material of the nanocrystalline flexible magnetic shielding sheet (2) is nanocrystalline material after magnetic fragmentation.

5. The wireless charging coil assembly according to claim 1, characterized in that, Also includes: The jig (3) is used to attach the coil (1) to the nanocrystalline flexible magnetic shielding sheet (2).

6. The wireless charging coil assembly according to claim 5, characterized in that, The fixture (3) has grooves (31) on its surface for placing and fixing the coil (1) and the nanocrystalline flexible magnetic shielding sheet (2).

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