Thin Printed Wireless Charging Coil Structure
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Solution Overview
Problem
Conventional wireless charging coils are complex, time-consuming to produce, and too thick, making them unsuitable for small and thin electronic devices like smartphones due to their large interior space requirements.
Innovation Solution
A wireless charging structure comprising a substrate, a decorative layer, a metal coil, and a shield layer, where the metal coil is formed on the decorative layer and covered by the shield layer, using a simple and less time-consuming method, and the metal coil is made of conductive materials like copper, silver, or graphene to achieve a thin and lightweight design.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a coil is formed by winding around a coil winding machine, then the coil can be produced with conventional methods, but the process is complicated and time-consuming
Solution Approach 1:
The patent replaces the conventional mechanical coil winding machine with a printing process that deposits conductive material directly onto the substrate to form the coil pattern. This substitution eliminates the complex mechanical winding operation and reduces production time significantly
Solution Approach 2:
The patent changes the formation method parameter from mechanical winding to material deposition/printing. This parameter change transforms the manufacturing process from a time-consuming multi-step winding operation to a faster single-step or multi-step printing process
2Volume of moving object
If a coil is formed by conventional winding methods, then the coil can be produced, but the thickness is too thick and occupies large interior space
Solution Approach 1:
The patent uses thin film deposition techniques to create the coil structure, resulting in a coil that is only 0.2-0.5mm thick. This thin film approach replaces the bulky wound coil structure with a planar, space-efficient design suitable for thin electronic devices
Solution Approach 2:
The patent transitions from a three-dimensional wound coil structure to a two-dimensional planar coil pattern printed on the substrate. This dimensional change reduces the thickness (z-dimension) while maintaining the electrical functionality through optimized trace routing in the x-y plane
3Power
If a thick coil is used for wireless charging, then the coil can provide sufficient power, but it occupies large interior space of the electronic device
Solution Approach 1:
The patent employs composite material structures including conductive traces, insulating layers, and protective coatings to achieve high power transfer efficiency in a thin profile. The multi-layer composite design allows for optimized electrical performance without increasing overall thickness
Solution Approach 2:
The patent changes the power delivery parameter optimization from thickness-based to pattern-based, using optimized trace width, spacing, and geometry in the printed coil design to achieve sufficient power transfer at reduced thickness
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 solution enables efficient wireless charging with a thin and lightweight coil structure, improving product yield and compatibility with small electronic devices by simplifying the manufacturing process and reducing the thickness of the wireless charging structure to 0.2-0.5 mm.
Implementation Method 1
The electromagnetic induction principle is applicable to the wireless charging technology. In detail, a primary coil at a power supply side is configured close to a secondary coil at a power receiving side. Then, the secondary coil is affected by the magnetic field from the primary coil to generate an induced current.
Data Source
AI summary
A wireless charging structure is provided. The wireless charging structure comprises: a substrate; a decorative layer disposed on the substrate; a metal coil disposed on the decorative layer; and a shield layer covering the metal coil. A method for forming a wireless charging structure is also provided.