Planar Coil Holding Structure to Prevent Floating and Warping
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Solution Overview
Problem
Existing planar coils used in wireless power transmission systems face issues such as floating from sheet materials due to poor adhesion and warping of holding members, which affect assembly and manufacturing efficiency, and the formation of deep grooves for magnetic walls reduces the strength and manufacturing difficulty of coil components.
Innovation Solution
The coil components incorporate projecting pieces and holding members with grooves and ribs to secure the planar coils, using mold formation techniques to prevent floating and warping, and design grooves to maintain strength and ease manufacturing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If the planar coil is embedded in the sheet material by heating and pressing, then the coil and sheet material are formed into a single body, but the planar coil floats away from the sheet material due to poor adhesion
Solution Approach 1:
The patent applies adhesive before heating and pressing the planar coil onto the sheet material. This preliminary application of adhesive ensures strong bonding between the coil and sheet material, preventing the coil from floating away during assembly and subsequent handling operations.
Solution Approach 2:
The patent introduces adhesive as an intermediary substance between the planar coil and sheet material. This adhesive layer mediates the bonding interface, creating reliable adhesion that prevents floating and ensures proper assembly, especially important when dealing with different materials that may have poor natural adhesion.
2Stability of the object's composition
If deep grooves are formed on the holding member for magnetic wall placement, then the planar coil is secured, but the holding member strength decreases and manufacturing becomes difficult
Solution Approach 1:
The patent forms grooves only in specific local regions of the holding member where magnetic walls need to be positioned, rather than creating deep grooves throughout the entire structure. This localized groove formation secures the planar coil at critical positions while preserving the overall structural strength of the holding member and facilitating easier manufacturing.
Solution Approach 2:
The patent implements partial groove formation - creating grooves only where necessary for coil securing rather than excessive deep grooves across the entire holding member. This partial action achieves the necessary coil positioning stability while minimizing the impact on holding member strength and manufacturing complexity.
3Ease of manufacture
If the holding member is formed into a single body with the planar coil, then assembly is simplified, but the holding member warps during manufacturing
Solution Approach 1:
The patent forms grooves and places magnetic walls into the holding member before the final bonding step that creates the single-body structure. This preliminary arrangement ensures proper positioning and prevents warping during the manufacturing process, while still achieving the simplified single-body assembly structure.
Solution Approach 2:
The patent creates the holding member with distinct functional regions - grooves for magnetic wall placement, flat regions for coil contact, and structural support portions. This segmentation allows each region to perform its specific function without interfering with others, preventing warping while maintaining the single-body integrated structure for easy assembly.
Data Source
AI summary
A coil component includes a first planar coil that includes multiple turn portions and a projecting piece that extends from an inner circumferential edge and/or an outer circumferential edge of at least one turn portion among the multiple turn portions and that bends such that the projecting piece leaves from the turn portion, and a first holding member that is in contact with the multiple turn portions of the first planar coil and that overlaps the first planar coil. The first holding member includes a groove on a first surface on which the first planar coil is stacked, and the projecting piece is in contact with an inner surface of the groove in a radial direction.