Planar Coil Array Bending for Low-Loss 3D Displacement Sensing
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Solution Overview
Problem
Existing manufacturing processes for coil arrays are complex and costly, with increased contact resistance at connection points, leading to higher coil resistance.
Innovation Solution
A planar coil array is formed by bending a flexible board with interconnected planar coils having angular deviations, allowing for a three-dimensional shape and simplified electrical connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If coil precursors are bent into cylindrical shape and terminals are connected, then three-dimensional coil shape is achieved, but manufacturing process becomes complicated and cost increases
Solution Approach 1:
The coil is divided into multiple planar coil units (first planar coil and second planar coil) that are arranged in a specific pattern on a flat flexible board. Each planar coil unit has a spiral shape with angular deviation from the center, allowing the entire coil to achieve three-dimensional functionality through planar segmentation rather than requiring complex three-dimensional winding processes.
Solution Approach 2:
The invention transitions from traditional three-dimensional cylindrical coil winding to a two-dimensional planar arrangement that can be easily manufactured on a flat flexible board. The angular deviation of spiral shapes in different planar coils creates effective three-dimensional magnetic field characteristics while maintaining planar manufacturing simplicity.
2Reliability
If terminals are connected after bending coil precursors, then electrical connection is completed, but contact resistance increases and coil resistance increases
Solution Approach 1:
Multiple planar coils are electrically connected in parallel by connecting corresponding terminals (first terminals and second terminals) to form a unified coil structure. This parallel connection merges the electrical paths, reducing overall resistance and eliminating the need for additional connection steps that would introduce contact resistance.
Solution Approach 2:
The electrical connections between planar coils are established beforehand during the board fabrication process using conductive patterns on the flexible board, rather than requiring post-assembly connection steps. This preliminary action ensures low-contact resistance connections are made under controlled manufacturing conditions.
3Shape
If planar coil array is manufactured by bending flexible board, then three-dimensional shape is realized, but manufacturing time and cost are reduced
Solution Approach 1:
The coil array is manufactured by forming conductive patterns on a flexible board that can be bent into three-dimensional shapes. The flexible board serves as both the structural support and the substrate for the conductive coil patterns, enabling simple bending-based fabrication that reduces manufacturing time and cost while achieving the required three-dimensional configuration.
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 reduces manufacturing time and costs while minimizing signal loss, enabling a high-gain displacement sensor with a low-loss transmission path.
Implementation Method 1
a first planar coil (SU1) having a first spiral shape in which a first conductor (310) is wound around a first center (50)
Data Source
AI summary
A three-dimensionally shaped coil can be manufactured at low cost and easily and uses a planar coil array. In the planar coil array, a flexible board comprises: a first planar coil that has a first spiral shape in which a first conductor is wound in a left-handed or right-handed manner with respect to a first center; and a second planar coil in which a second conductor in the same layer as the first conductor formed on the flexible board is wound with respect to a second center in the same manner of winding as the first coil, the second planar coil having an angular misalignment from the first spiral shape, being disposed adjacent to the first planar coil in a predetermined direction, and being electrically connected to the first planar coil. The flexible board is bent, thereby forming a three-dimensionally shaped coil.