Integrated-Capacitance Resonant Coils Using Segmented Dielectrics
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Solution Overview
Problem
Existing resonant coils with integrated capacitance face challenges in achieving high performance due to the high dielectric loss of standard materials like polyimide, making it difficult and costly to manufacture them using standard PCB techniques, and requiring expensive low-loss dielectric materials.
Innovation Solution
The design minimizes the electric field in the dielectric material between conductor sublayers, allowing for high-performance resonant coils even with high-loss materials like FR4 or polyimide, using a configuration with alternating conductor layers and separation dielectric layers, where the sublayer dielectric layers can be of varying thickness without affecting performance, and employing a magnetic core to direct the magnetic field and reduce losses.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If standard dielectric materials like polyimide are used in resonant coils, then manufacturing cost and ease of manufacture are improved, but dielectric loss increases and performance deteriorates
Solution Approach 1:
The dielectric structure is segmented into two distinct parts: sublayer dielectric layers (110) between conductor sublayers and separation dielectric layers (112) between adjacent conductor layers. This segmentation allows different dielectric materials to be used in different segments, with the sublayer dielectric layers using inexpensive standard materials like polyimide and the separation dielectric layers using low-loss materials, thereby resolving the contradiction between manufacturing cost and dielectric loss.
Solution Approach 2:
Different regions of the dielectric structure are assigned different material properties. The sublayer dielectric layers use standard high-loss materials for cost-effective manufacturing, while the separation dielectric layers use low-loss materials to maintain overall coil performance. This local differentiation of material quality allows the system to achieve both low cost and low energy loss.
2Loss of energy
If low-loss dielectric materials like PTFE are used, then dielectric loss is reduced and performance is improved, but manufacturing cost increases
Solution Approach 1:
The dielectric structure is segmented into two distinct parts: sublayer dielectric layers (110) between conductor sublayers and separation dielectric layers (112) between adjacent conductor layers. This segmentation allows different dielectric materials to be used in different segments, with the sublayer dielectric layers using inexpensive standard materials like polyimide and the separation dielectric layers using low-loss materials, thereby resolving the contradiction between manufacturing cost and dielectric loss.
Solution Approach 2:
Different regions of the dielectric structure are assigned different material properties. The sublayer dielectric layers use standard high-loss materials for cost-effective manufacturing, while the separation dielectric layers use low-loss materials to maintain overall coil performance. This local differentiation of material quality allows the system to achieve both low cost and low energy loss.
3Reliability
If alternating conductor layers with different orientations are used, then integrated capacitance is achieved and resonance is improved, but device complexity increases
Solution Approach 1:
The inductor and capacitor functions are merged into a single integrated structure. The alternating conductor layers with different orientations create both inductive and capacitive effects simultaneously, eliminating the need for separate external reactive components. This merging achieves resonance performance while the systematic stacking pattern keeps the structure relatively simple.
Solution Approach 2:
The conductor layers serve multiple functions: they provide inductance through their winding configuration and capacitance through their alternating orientations and spacing. This multi-functionality allows the same structural elements to achieve both resonance and integrated capacitance without requiring additional separate components, thereby managing complexity while improving performance.
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 use of low-cost manufacturing techniques and materials while maintaining high performance, achieving quality factors over 1000 and higher efficiency in wireless power transfer applications compared to conventional resonant coils.
Implementation Method 1
The design minimizes the electric field in the dielectric material between conductor sublayers
Implementation Method 2
to generate a magnetic field for uses such as induction heating, magnetic hyperthermia and wireless power transfer
Implementation Method 3
these resonant coils can achieve resonance without external reactive components, when part of an electrical circuit
Implementation Method 4
employing a magnetic core to direct the magnetic field and reduce losses
Data Source
AI summary
A resonant coil with integrated capacitance includes at least one separation dielectric layer and a plurality of conductor layers stacked in an alternating manner. Each of the plurality of conductor layers includes a first conductor sublayer and second conductor sublayer having common orientation and a sublayer dielectric layer separating the first and second conductor sublayers. Adjacent conductor layers of the plurality of conductor layers have different orientations.