Multilayer Coil for Wireless Power Transfer
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Solution Overview
Problem
Current coil designs for wireless power transfer face challenges in efficiently guiding magnetic fields and reducing eddy currents, which affect the transfer efficiency and Q factor in wireless charging systems.
Innovation Solution
The use of a multilayer film with alternating electrically conductive and magnetically insulative layers, where each loop includes a magnetically conductive layer and a soft magnetic layer, forming a regular pattern of concentric loops with varying edge surface angles and adhesive layers to optimize magnetic field concentration and reduce electrical resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a single-layer coil design is used, then the device complexity is low, but the magnetic field guidance efficiency and eddy current reduction are insufficient
Solution Approach 1:
The coil is divided into multiple functional layers with distinct properties: electrically conductive layers for current flow, magnetically insulative layers to reduce eddy currents, and magnetically conductive layers for field concentration. This segmentation allows each layer to perform its specific function optimally, resolving the contradiction between transfer efficiency and structural complexity.
Solution Approach 2:
The patent employs composite multilayer structures combining materials with different electrical and magnetic properties. This composite approach enables simultaneous achievement of high transfer efficiency through optimized magnetic field guidance and reduced eddy currents, while maintaining a manageable structural complexity through systematic layering.
2Reliability
If magnetically conductive layers are added to concentrate magnetic fields, then the magnetic field concentration improves, but eddy currents increase due to enhanced magnetic coupling
Solution Approach 1:
The patent extracts and separates the harmful eddy current paths from the useful magnetic field concentration function by introducing magnetically insulative layers between conductive layers. This extraction allows the magnetically conductive layers to concentrate fields while the insulative layers block eddy current formation, resolving the contradiction between field concentration and eddy current reduction.
Solution Approach 2:
Magnetically insulative layers serve as intermediaries between magnetically conductive layers, enabling magnetic field concentration while preventing direct magnetic coupling that would generate eddy currents. These intermediary layers decouple the contradictory requirements of field concentration and eddy current suppression.
3Object-generated harmful factors
If multiple alternating layers are used to reduce eddy currents, then the eddy current reduction improves, but the manufacturing complexity increases
Solution Approach 1:
The patent merges multiple functional requirements into a unified multilayer manufacturing process where electrically conductive, magnetically insulative, and magnetically conductive layers are deposited or assembled in a systematic sequence. This merging approach reduces manufacturing complexity compared to assembling separate components, while still achieving effective eddy current reduction through the alternating 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 enhances the transfer efficiency of wireless charging by concentrating magnetic fields and reducing eddy currents, thereby improving the Q factor and overall performance of wireless charging systems.
Implementation Method 1
concentrating magnetic fields
Implementation Method 2
reducing eddy currents
Implementation Method 3
Inductive coupling between coils can be used in wireless power systems
Data Source
AI summary
A coil for transfer of information or energy is described. The coil includes an electrically conductive magnetically insulative first layer and a magnetically conductive second layer bonded to the first layer along the length of the first layer. The first and second layers are wound to form a plurality of substantially concentric loops. A width and a length of the second layer may be substantially co-extensive with a respective width and length of the first layer so as to expose opposing longitudinal edge surfaces of the first layer along the length of the first layer. At least one of the opposing longitudinal edge surfaces may include a regular pattern extending substantially along a same first direction and across substantially the entire coil. A method of making the coil is described.