Multilayer Wireless Charging Coil Winding for Limited Coil Space
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Solution Overview
Problem
The low electromagnetic coupling coefficient between transmitter and receiver coils in small-scale electronic devices results in low charging efficiency due to size limitations, leading to reduced induced voltage and inefficient wireless charging.
Innovation Solution
A multi-layer, multi-turn wireless charging coil design is implemented, utilizing various winding methods such as parallel, series, and series-parallel configurations to optimize impedance and Q value, maximizing coil thickness and width usage, and reducing coil loss.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a winding guide is used to improve winding precision, then manufacturing precision is improved, but device complexity increases due to additional components and alignment requirements
Solution Approach 1:
The winding guide utilizes the magnetic field generated by the voice coil motor itself to guide the winding process, eliminating the need for external alignment mechanisms. The motor's own magnetic field serves the dual purpose of actuation and positioning guidance
Solution Approach 2:
The voice coil motor performs multiple functions: it provides the driving force for the winding process and simultaneously serves as the positioning mechanism through its magnetic field, eliminating the need for separate alignment devices
2Device complexity
If manual winding is used to reduce device complexity, then device complexity is reduced, but productivity decreases due to time-consuming alignment and winding processes
Solution Approach 1:
The patent replaces manual mechanical winding operations with an automated system that uses magnetic field-based positioning and control, enabling machine-driven precision winding without complex mechanical alignment mechanisms
Solution Approach 2:
The system dynamically adjusts control parameters such as driving voltage, frequency, and magnetic field strength during the winding process to optimize both speed and precision, enabling high-speed automated winding
3Manufacturing precision
If complex alignment mechanisms are used to improve winding precision, then manufacturing precision is improved, but ease of manufacture worsens due to difficult assembly and calibration
Solution Approach 1:
The winding guide system uses the motor's own magnetic field for positioning, eliminating the need for separate alignment mechanisms that would require complex assembly and calibration procedures
Solution Approach 2:
The patent extracts the alignment function from separate mechanical components and integrates it into the motor's magnetic field control, simplifying the overall structure and easing manufacturing
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 design enhances wireless charging efficiency by increasing induced current and reducing coil loss, while allowing for flexible coil shapes and improved compatibility with limited device sizes.
Implementation Method 1
a driving signal is then input into the voice coil motor to drive the winding guide and the coil wire
Data Source
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Figure 5A~5B
AI summary
This application discloses a wireless charging coil winding method, an electronic device, and a communication system. In the wireless charging coil winding method, based on specifications (for example, a coil thickness and a coil winding width) of a coil to be designed, a coil of any quantity of layers and any quantity of turns can be obtained through combination in any one or more of the following manners: an N-layer 1-turn coil whose N layers of wires are wound in parallel, an N-layer N-turn coil whose N layers of wires are wound in series, an N-layer M-turn coil (N>M) whose N layers of wires are series-parallel-wound and a part of wires are wound in series, and the like. In this way, in a case in which a size of the coil is limited, a multi-layer multi-turn wound coil is designed, and limited coil thickness space, a limited coil winding width, and the like can be fully used, to obtain an optimal impedance and Q value, reduce coil loss, and improve wireless charging efficiency.