Laminated Flat Coil Module for Scalable Wireless Charging
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Solution Overview
Problem
Existing wireless charging technologies face challenges in connecting start points during spot welding and lack standardization, making it difficult to implement chargers of various capacities and complicating manufacturing and installation.
Innovation Solution
A flat coil-type wireless charging module and power supply are designed with laminated multilayer configurations of plastic sheets, featuring conductive patterns in spiral shapes with exposed electrodes, plated through holes for electrical connections, and a cartridge system for easy assembly and connection to external power sources.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If traditional coil assemblies are used for wireless charging, then wireless charging function is achieved, but it is difficult to connect start points during spot welding and difficult to implement chargers of various capacities due to lack of standardization
Solution Approach 1:
The coil assembly is divided into multiple standardized plastic sheets that can be laminated in different quantities to create chargers of various capacities. Each sheet has standardized conductive patterns and electrodes, allowing modular assembly without requiring complex spot welding connections.
Solution Approach 2:
The standardized plastic sheets with uniform conductive patterns and electrode configurations can serve multiple purposes and be used in different charger capacities. The same basic unit can be laminated in various quantities to create different power level chargers, providing universal applicability across product lines.
2Reliability
If complex coil assemblies are used, then wireless charging capability is achieved, but manufacturing and installation become complicated
Solution Approach 1:
The conductive patterns and electrodes are pre-formed on the plastic sheets during manufacturing, and the sheets are pre-laminated in standardized configurations. This preliminary preparation simplifies the final assembly process, as the complex coil structures are already prepared in modular units ready for installation.
Solution Approach 2:
The coil assembly uses thin plastic sheets with conductive patterns instead of traditional bulky coil structures. These flexible thin film structures maintain the necessary electromagnetic properties while being easier to manufacture, handle, and install in various configurations.
3Power
If traditional coil structures are used, then electromagnetic induction is achieved, but compact manufacturing and flexible application are hindered
Solution Approach 1:
The patent uses thin plastic sheets with conductive patterns to create compact coil structures that maintain effective electromagnetic induction while significantly reducing the overall volume. The thin film construction allows the charger to be more compact while preserving the necessary power transmission capability.
Solution Approach 2:
The coil assembly combines plastic sheets with conductive patterns to create a composite structure that integrates structural support, electrical conduction, and electromagnetic functionality in a single compact unit. This composite approach eliminates the need for separate components, reducing overall size while maintaining power capability.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution enables the production of chargers and transformers with various capacities, facilitating easy manufacturing, installation, and compact design, allowing for flexible application based on installation needs.
Implementation Method 1
each plastic sheet has a predetermined conductive pattern integrally formed thereon to form a magnetic circuit used for magnetic induction or resonance induction
Implementation Method 2
each plastic sheet has a predetermined conductive pattern integrally formed thereon to form a magnetic circuit used for magnetic induction or resonance induction
Implementation Method 3
the conductive pattern is electrically connected to the other electrode through a plated through hole
Data Source
AI summary
A flat coil-type wireless charging module and power supply where the module includes flat coils as laminated structures of one or more plastic sheets having a conductive pattern configured to form a magnetic circuit and formed in a C shape or a spiral shape having a predetermined width such that electrodes are connected to both ends thereof. The flat coil-type power supply has a configuration in which a conductive pattern is formed in a C shape or a spiral shape with a predetermined width on the upper surface of each of flat coils including one or more plastic sheets to form a magnetic circuit used for magnetic induction or resonance induction, electrodes are connected to both ends thereof, and a core space of a predetermined area are formed through the center of the conductive pattern so that a core is mounted therein.