3D-Coil Transponder Structure for Shorter Wire Length and Lower Loss
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Solution Overview
Problem
Conventional 3D-coil transponders have a plastic thickness at the bottom of their magnetic body, leading to longer wire lengths for coil formation, increased loss, and larger size.
Innovation Solution
A structure with no plastic thickness at the bottom of the magnetic body, featuring separated groups of leads encapsulated by insulating molding bodies, with coils winding around X, Y, and Z axes, and a protection layer, using enameled wires and ferrite magnetic bodies, to reduce wire length and size.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a plastic thickness is provided at the bottom of the magnetic body, then the magnetic body is protected and leads are insulated, but the wire length for forming the coil increases
Solution Approach 1:
The patent transitions from a conventional planar structure with uniform plastic thickness to a three-dimensional structure where the plastic substrate has varying thickness. The magnetic body is positioned at a specific height above the plastic substrate, creating a vertical dimension that optimizes coil wire length while maintaining protection and insulation functions.
Solution Approach 2:
The patent changes the thickness parameter of the plastic substrate from a uniform value to a non-uniform distribution, with the thickness varying at different locations. This allows the wire to follow an optimized path around the magnetic body, reducing the overall wire length while maintaining adequate insulation and protection.
2Length of moving object
If the wire length is increased, then the coil can surround the magnetic body, but the loss increases
Solution Approach 1:
By optimizing the wire length through controlled plastic thickness variation and strategic magnetic body positioning, the patent reduces the total wire length required for coil formation. Since resistive losses are directly proportional to wire length, this parameter optimization directly reduces energy loss in the coil.
3Length of moving object
If the wire length is increased, then the coil can surround the magnetic body, but the size of the transponder increases
Solution Approach 1:
The patent utilizes vertical positioning of the magnetic body above the plastic substrate to create a compact three-dimensional configuration. This allows the coil to surround the magnetic body efficiently in three dimensions, reducing the horizontal footprint and overall transponder size compared to a planar configuration.
Solution Approach 2:
The patent employs a nested structure where the coil is wound around the magnetic body, which itself is positioned above the plastic substrate. This nested arrangement optimizes space utilization and minimizes the overall transponder volume while maintaining functional integrity.
Data Source
AI summary
A structure for forming a 3D-coil transponder, wherein each group of leads is encapsulated by a separated insulating molding body and a magnetic body disposed over the plurality of separated groups of leads, wherein each said insulating molding body does not extend across two or more groups of leads.