Planar Coil Unit Thickness Reduction via Magnetic Sheet Integration
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Solution Overview
Problem
Existing non-contact power transmission coil units face challenges in reducing size, particularly thickness, while maintaining efficiency and productivity, as previous technologies either increase heat generation or complicate the manufacturing process.
Innovation Solution
A coil unit configuration featuring a planar coil placed within a planar coil placement section on a printed circuit board, protected by a thermal conductivity-enhanced protective sheet and positioned with a magnetic sheet on the non-transmission side, allowing for reduced thickness and efficient heat dissipation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of stationary object
If metal sheets are disposed on the back side of antenna and magnetic material to reduce thickness, then the non-contact IC card is stably written/read without being affected by surrounding metal, but the metal sheet produces heat when applying to non-contact power transmission
Solution Approach 1:
The patent extracts the metal sheet from the coil unit structure, eliminating the heat generation problem associated with metal sheets in non-contact power transmission applications. The design achieves thickness reduction through other means (planar coil integration and optimized magnetic sheet usage) without relying on metal sheets that would cause thermal issues.
2Length of stationary object
If metal sheets are used to reduce thickness, then the coil unit thickness is reduced, but it is necessary to tune each antenna which deteriorates mass productivity and increases cost
Solution Approach 1:
The patent creates a universal coil unit design where the planar coil integrated on the printed circuit board with the magnetic sheet provides consistent performance without requiring individual tuning. This standardized configuration can be mass-produced using conventional PCB manufacturing techniques, significantly improving productivity and reducing costs compared to tuned antenna designs.
3Volume of moving object
If a flexible printed circuit board is used to reduce size, then the non-contact power transmission module size is reduced, but the coil placement shape cannot be formed when using a sheet-shaped magnetic material
Solution Approach 1:
The patent employs a rigid printed circuit board with the planar coil formed in a plane, allowing the coil placement shape to be precisely defined by the PCB geometry. This approach accommodates sheet-shaped magnetic materials effectively, as both the planar coil and magnetic sheet can be laid out in two dimensions on the PCB, simplifying the manufacturing process while reducing overall module size.
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
The configuration enables a compact coil unit with enhanced transmission efficiency and simplified manufacturing, reducing thermal resistance and maintaining stable ground potential while facilitating easy assembly and heat dissipation.
Implementation Method 1
non-contact power transmission has been known which enables power transmission without metal-to-metal contact utilizing electromagnetic induction
Implementation Method 2
a magnetic sheet that is provided on the non-transmission side of the planar coil
Implementation Method 3
a protective sheet that is provided on the transmission side of the planar coil and protects the planar coil
Data Source
AI summary
A coil unit includes a planar coil, a printed circuit board that includes a planar coil placement section that receives the planar coil, a protective sheet that is provided on a transmission side of the planar coil and protects the planar coil, and a magnetic sheet that is provided on a non-transmission side of the planar coil. The planar coil is placed in the planar coil placement section and is electrically connected to the printed circuit board. The planar coil placement section has a shape that corresponds to an external shape of the planar coil.