Multilayer Concentric Coil Structure for Space-Saving Wireless Charging
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Solution Overview
Problem
Portable electronic devices face increased manufacturing costs and reduced precision in etching thick copper sheets for improved wireless charging efficiency, and the separate manufacturing of coils for different functions leads to space occupation and prolonged production time.
Innovation Solution
A coil design featuring a multilayer film with concentric loops, including an innermost, outermost, and intermediate loop, with coextensive electrical and magnetic conduction layers and adhesive layers, allowing for simultaneous function provision and reduced space occupation, along with a flexible circuit board and terminal units for efficient power transmission.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the copper sheet is manufactured to be thick to increase wireless charging efficiency, then wireless charging efficiency is improved, but manufacturing cost increases and etching precision is degraded
Solution Approach 1:
The coil structure is divided into multiple thin copper sheets stacked together to form a thick coil assembly. Each thin sheet can be precisely etched separately, while the stacked configuration achieves the desired thickness for efficient wireless charging. This segmentation allows maintaining etching precision while achieving the required overall thickness.
Solution Approach 2:
Multiple copper sheets are combined with adhesive layers to create a composite coil structure. The composite construction allows each copper sheet to be individually manufactured with high precision through etching, while the stacked composite achieves the necessary thickness for optimal wireless charging performance.
2Adaptability or versatility
If multiple independent coils are manufactured separately to perform different functions, then functional versatility is improved, but space occupation increases and production cost increases
Solution Approach 1:
Multiple coils for different functions (wireless charging, NFC, MST) are merged into a single integrated coil structure. Different regions of the same coil assembly perform different functions, eliminating the need for separate independent coils and reducing overall space occupation while maintaining functional versatility.
Solution Approach 2:
The coil structure is designed to serve multiple functions simultaneously. By configuring different segments of the coil with appropriate electrical connections and orientations, a single coil assembly can provide wireless charging, NFC communication, and MST payment functions, making the system universal and multi-functional.
3Adaptability or versatility
If multiple independent coils are manufactured separately, then functional versatility is improved, but production time increases
Solution Approach 1:
The manufacturing process merges multiple coil production steps into a single integrated process. Multiple copper sheets are etched, stacked with adhesive layers, and bonded together in one production cycle, significantly reducing the total production time compared to manufacturing separate coils independently and assembling them later.
Solution Approach 2:
Multiple copper sheets are prepared with their respective patterns in advance through etching, then stacked and bonded together in a single operation. This preliminary preparation of multiple layers followed by one-step assembly reduces overall production time compared to sequential manufacturing and assembly of separate coils.
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 design enhances space utilization, reduces production costs, and shortens the time required for manufacturing multiple coils, improving the competitiveness of portable electronic devices by integrating multiple functions into a single coil system.
Implementation Method 1
Such a wireless charging system (wireless power charging (WPC)) transmits and receives power by using electromagnetic induction or resonance
Implementation Method 2
a second magnetic conduction layer, and a third adhesive layer, wherein the second magnetic conduction layer is coupled with the first electrical conduction layer by the third adhesive layer
Data Source
AI summary
The present disclosure relates to a coil and an electrical system. According to an embodiment of the present disclosure, specifically, there is provided a coil including: main coil surfaces which face each other and are substantially planar; and a multilayer film which is wound to form a plurality of loops which are substantially concentric, wherein the plurality of loops include an innermost loop including a first longitudinal end of the multilayer film, a first intermediate loop, and an outermost loop including a second longitudinal end of the multilayer film, wherein the multilayer film includes a first electrical conduction layer, a second magnetic conduction layer, and a third adhesive layer, wherein the second magnetic conduction layer is coupled with the first electrical conduction layer by the third adhesive layer, wherein the first electrical conduction layer, the second magnetic conduction layer, and the third adhesive layer have widths and lengths which are substantially coextensive with one another, such that the main coil surfaces which are substantially planar include corresponding end surfaces of the first electrical conduction layer, the second magnetic conduction layer, and the third adhesive layer, respectively, wherein the first intermediate loop is disposed between the innermost loop and the outermost loop, wherein a first electro-conductive terminal is terminated on the first electrical conduction layer of the first intermediate loop.