Flexible Coil Substrate Design for High-Productivity Manufacturing
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing technologies face challenges in increasing the number of coil substrates that can be efficiently manufactured from a single substrate, as they often result in limited product output due to design constraints.
Innovation Solution
A coil substrate design featuring a first flexible substrate with coils, a second flexible substrate extending from the first, and wiring formed on the second substrate, where the second substrate includes a first portion extending from the first and a second portion along the first substrate, creating a gap, allowing for efficient formation of multiple coil substrates by folding and winding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a conventional single-layer substrate design is used for coil substrates, then the manufacturing process is simple, but the number of coil substrates that can be efficiently manufactured from a single substrate is limited
Solution Approach 1:
The substrate is divided into multiple independent flexible substrate regions (first flexible substrate, second flexible substrate, third flexible substrate) that can be separately formed into coil substrates. Each region contains its own coil patterns and wiring, allowing the single substrate to be segmented into multiple functional units that can be independently manufactured into separate coil substrates, thereby increasing productivity.
Solution Approach 2:
The patent transitions from a conventional single-layer planar design to a multi-layer three-dimensional structure with flexible substrates extending in different directions and levels. The first, second, and third flexible substrates are arranged in spatial relationships that allow multiple coil substrates to be formed from a single substrate, utilizing vertical and lateral dimensions to maximize substrate utilization.
2Productivity
If the substrate design allows multiple coil substrates to be formed, then manufacturing efficiency increases, but the design constraints and complexity increase
Solution Approach 1:
The single substrate serves multiple functions by incorporating multiple flexible substrate regions that can each be formed into separate coil substrates. The substrate acts as both a support structure and a manufacturing template, providing universal functionality that enables the production of multiple different coil substrates from a single base structure, thereby improving manufacturing efficiency without proportionally increasing design constraints.
Data Source
AI summary
A coil substrate includes a first flexible substrate, a coil formed on the first flexible substrate, a second flexible substrate extending from the first flexible substrate, and a wiring that is formed on the second flexible substrate and is electrically connected to the coil formed on the first flexible substrate. The second flexible substrate includes a first portion extending from the first flexible substrate and a second portion extending from the first portion such that the second portion is formed along the first flexible substrate and that the second flexible substrate forms a gap between the second portion and the first flexible substrate.