Magnetic Excitation Coil Structure With Flexible Substrate
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Solution Overview
Problem
Existing magnetic coil structures face limitations in increasing winding density, which restricts the aspect ratio and hinders further improvement in magnetic flux and electromagnetic effects, thereby affecting overall performance and application fields.
Innovation Solution
A magnetic excitation coil structure is developed with a thin magnetic coil sheet rolled into a cylindrical body, featuring a flexible substrate, dielectric layer, and patterned circuit layers made of conductive material, allowing for an aspect ratio up to 2:1 or 1:2, and covered with an insulation layer, enabling higher winding density and efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional enameled wire is used to form coils, then the manufacturing process is simple, but the winding density is limited and the aspect ratio cannot be increased beyond 2:1 or 1:1
Solution Approach 1:
The patent uses a flexible substrate as the base for the coil structure, allowing the circuit pattern to be formed on a thin, flexible surface that can be rolled into cylindrical shapes with high winding density. This flexible film approach enables aspect ratios of 1:2 or higher while maintaining structural integrity and electrical performance.
Solution Approach 2:
The patent employs a composite structure consisting of a flexible substrate, dielectric layer, and patterned circuit layer. This multi-layer composite design integrates mechanical support, electrical insulation, and conductive pathways into a single unified structure that achieves high winding density without compromising manufacturing feasibility.
2Power
If the aspect ratio of the coil is increased to improve magnetic flux, then the electromagnetic effect is enhanced, but the manufacturing difficulty increases with traditional rigid board technology
Solution Approach 1:
The flexible substrate enables the coil to achieve high aspect ratios (1:2 or higher) by allowing the circuit pattern to be formed on a thin surface that can be efficiently rolled into compact cylindrical shapes. This flexibility dramatically simplifies the manufacturing of high-aspect-ratio coils compared to rigid board technologies.
Solution Approach 2:
The patent replaces traditional mechanical winding processes with a printed circuit board approach where the circuit pattern is directly formed on the flexible substrate. This substitution eliminates the limitations of mechanical winding and enables precise control of the circuit geometry to achieve optimal magnetic flux with simplified manufacturing.
3Reliability
If rigid board technology is used to increase winding density, then the electrical property is improved, but the aspect ratio is limited to 2:1 or 1:1
Solution Approach 1:
The flexible substrate allows the coil structure to achieve aspect ratios of 1:2 or higher by enabling the circuit pattern to be formed on a thin surface that can be rolled into compact cylindrical shapes. This flexibility overcomes the geometric constraints of rigid board technology while maintaining reliable electrical connections.
Solution Approach 2:
The patent transitions from planar rigid board structures to three-dimensional rolled cylindrical structures. By utilizing the radial dimension and rolling the flexible substrate into a cylinder, the design achieves higher effective winding density and aspect ratio while maintaining electrical reliability through the integrated multi-layer structure.
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
This configuration significantly increases the magnetic flux and electromagnetic effect by enhancing winding density and electrical performance, while maintaining lower manufacturing costs and compatibility with current equipment.
Implementation Method 1
the patterned circuit layers are formed of an electrically conductive material and horizontally configured in the flexible substrate... the magnetic excitation coil structure possesses an electrical function of coil and can be used as an inductor to implement a magnetic excitation coil
Data Source
AI summary
Disclosed is a magnetic excitation coil structure including a magnetic coil sheet formed of a thin film and rolled as a cylindrical body with a hollow hole, and an insulation layer covering the outer surface of the cylindrical body formed by the magnetic coil sheet for protection. The magnetic coil sheet includes a flexible substrate, a dielectric layer attached to the flexible substrate, and a plurality of patterned circuit layers embedded in the flexible substrate and in contact with the dielectric layer. Each patterned circuit layer is separate, and the upper surfaces of the patterned circuit layers and the upper surface of the flexible substrate form a co-plane. The magnetic coil structure provides an electrical function of coil, which is enhanced by the patterned circuit layer due to its high aspect ratio of the electrical circuit, thereby greatly increasing the whole magnetic flux and electromagnetic effect.