PCB Wireless Power Antenna Coils With Laser-Etched Narrow Gaps
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Solution Overview
Problem
Existing methods for manufacturing wireless power transfer antennas on printed circuit boards (PCBs) are limited by the precision of the etching process, which restricts the achievement of narrow gap widths and optimal electrical characteristics.
Innovation Solution
The use of a combination of laser cutting and chemical etching to manufacture wireless power transfer antennas on PCBs, allowing for precise control over gap widths and turn widths, thereby enhancing the electrical characteristics and efficiency of the antennas.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If chemical etching is used to manufacture antenna coils on PCB, then the manufacturing process is efficient and suitable for mass production, but the gap width and turn width precision are limited and cannot achieve narrow gaps
Solution Approach 1:
The manufacturing process is segmented into two distinct stages: laser cutting for defining the coil geometry and chemical etching for removing excess material. This segmentation allows each process to optimize for its specific function, with laser cutting achieving precise narrow gaps and chemical etching providing efficient material removal suitable for mass production.
Solution Approach 2:
The laser cutting process performs preliminary action by pre-defining the coil geometry and gap locations before chemical etching. This preliminary structuring enables the subsequent etching process to work more efficiently with clearly defined boundaries, improving both precision and manufacturing efficiency.
2Productivity
If laser cutting alone is used to define antenna coils, then narrow gap widths can be achieved, but manufacturing efficiency and cost-effectiveness decrease
Solution Approach 1:
The patent merges laser cutting and chemical etching into a hybrid manufacturing process. Laser cutting provides the precision for narrow gaps while chemical etching contributes manufacturing efficiency through its ability to rapidly remove material. The combination leverages the strengths of both processes to achieve high productivity with precise gap widths.
Solution Approach 2:
The laser-cut defined geometry acts as an intermediary structure that guides the chemical etching process. The pre-cut coil shapes and gap locations serve as templates that direct where etching should occur, enabling the etching process to work more efficiently and achieve consistent results across mass production.
3Reliability
If conventional etching processes are used, then mass production is feasible, but the quality factor (Q) and equivalent series resistance (ESR) of the antennas are suboptimal
Solution Approach 1:
The manufacturing process is segmented into two distinct stages: laser cutting for defining the coil geometry and chemical etching for removing excess material. This segmentation allows each process to optimize for its specific function, with laser cutting achieving precise narrow gaps and chemical etching providing efficient material removal suitable for mass production.
Solution Approach 2:
The laser cutting process performs preliminary action by pre-defining the coil geometry and gap locations before chemical etching. This preliminary structuring enables the subsequent etching process to work more efficiently with clearly defined boundaries, improving both precision and manufacturing efficiency.
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 approach enables the production of antennas with improved quality factor (Q) and equivalent series resistance (ESR), leading to increased efficiency and performance, particularly at lower operating frequencies.
Implementation Method 1
laser cutting the first sheet within the coil area, based on a laser cutting path
Implementation Method 2
substantially exposing the first sheet to an etching solution, the etching solution substantially removing first portions of the conductive metal from the substrate
Data Source
AI summary
A PCB for wireless power transfer includes an antenna and the antenna includes a coil. A method for manufacturing the PCB includes providing a prefabricated PCB, the prefabricated PCB including a PCB design and a first area and providing a first sheet of a conductive metal for the first area. The method includes applying an etch resistant coating on a coil area within the first area and laser cutting the first sheet within the coil area, based on a laser cutting path for a first plurality of turns for a first layer of the coil, the first geometry configured wireless power transfer. The method further includes substantially exposing the first sheet to an etching solution, the etching solution substantially removing first portions of the conductive metal from the substrate to define, at least, first turn gaps between at least two of the first plurality of turns.