3D Printed Wireless Charging Coil on PCB
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Solution Overview
Problem
Conventional wireless charging systems require a Litz wire coil, which involves complex manufacturing processes and attachment to a printed circuit board, making it challenging for commercialization of small wireless charging systems.
Innovation Solution
A method and system for manufacturing a coil directly on a printed circuit board using a 3D metal printer to generate additional metal patterns, eliminating the need for Litz wire by creating a coil-shaped metal pattern and bonding a metal body to the additional pattern.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a Litz wire coil is used for wireless charging, then the coil can be manufactured with conventional methods, but the manufacturing process becomes complex and requires attachment to a printed circuit board
Solution Approach 1:
The patent merges the coil manufacturing process with the printed circuit board fabrication process by directly forming the coil pattern on the PCB substrate using a 3D metal printer. This integration eliminates the need for separate Litz wire preparation and attachment steps, thereby simplifying the overall manufacturing process while reducing device complexity.
Solution Approach 2:
The patent extracts the coil structure from the conventional Litz wire form and reimagines it as a direct metal pattern deposited on the PCB. This extraction allows the coil to be manufactured as an integral part of the circuit board rather than as a separate component requiring assembly.
2Ease of manufacture
If a Litz wire coil is used for wireless charging, then the coil can be manufactured with conventional methods, but attachment to printed circuit board is required
Solution Approach 1:
The patent combines the coil structure with the PCB substrate by directly depositing the metal pattern onto the board. This merging eliminates the attachment step entirely, as the coil becomes an intrinsic part of the PCB rather than a separate component that needs to be mounted.
Solution Approach 2:
The patent segments the coil manufacturing into a direct deposition process on the PCB, allowing the coil to be formed as a continuous metal pattern rather than as assembled wire segments. This segmentation approach simplifies the overall process by eliminating attachment operations.
3Adaptability or versatility
If a 3D metal printer is used to generate additional metal pattern on the coil, then direct manufacturing on PCB is achieved, but manufacturing process complexity increases
Solution Approach 1:
The patent replaces conventional mechanical coil assembly methods with a 3D metal printing process that directly deposits metal patterns on the PCB. This substitution enables on-board charging capability while the automated nature of 3D printing helps manage the complexity of the manufacturing system.
Solution Approach 2:
The patent changes the manufacturing parameters from conventional wire-based assembly to direct metal deposition with controlled layer thickness and pattern geometry. These parameter changes enable the coil to be integrated directly onto the PCB, providing on-board charging capability while the precision of 3D printing controls the resulting system complexity.
Data Source
AI summary
A method and system for manufacturing a coil for wireless charging are disclosed herein. The method may include manufacturing a printed circuit board, generating a coil-shaped metal pattern on the printed circuit board, and generating an additional metal pattern on the top of the metal pattern using a 3D metal printer.