Stacked Planar Coil Spacer Layout for Insulation and Magnetic Performance
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Solution Overview
Problem
Existing wireless power transmission systems face challenges in maintaining insulation and performance when stacking planar coils due to reduced spacing, which can lead to dielectric breakdown or short circuits, while also requiring high manufacturing costs and effort for large coils.
Innovation Solution
A coil component design featuring stacked planar coils with a spacer member that maintains an uneven interval and thickness, utilizing a magnetic-material-containing portion and non-magnetic portions to ensure insulation and performance without increasing size.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of moving object
If the interval between stacked planar coils is decreased to improve coil performance and reduce thickness, then the thickness of the device is reduced, but dielectric breakdown or short circuit becomes likely to occur between the coils
Solution Approach 1:
The spacer member features non-uniform thickness distribution, with thicker portions positioned at locations where electric field intensity is higher between adjacent planar coils. This local quality variation provides enhanced insulation precisely where needed, allowing the overall interval between coils to be minimized while preventing dielectric breakdown at critical points.
Solution Approach 2:
The spacer member acts as an intermediary component inserted between the stacked planar coils. It provides electrical insulation and mechanical spacing, enabling the coils to be positioned at minimal intervals while preventing direct contact and reducing the risk of short circuits or dielectric breakdown.
2Volume of moving object
If multiple planar coils are stacked with small intervals to improve performance and reduce size, then the device size is reduced, but insulation is compromised
Solution Approach 1:
The spacer member is designed with spatially varying thickness, providing localized insulation enhancement at positions where electric field concentration is highest between stacked coils. This allows minimal overall spacing while maintaining insulation reliability throughout the structure.
Solution Approach 2:
The spacer member comprises a composite structure combining magnetic material particles dispersed in a resin matrix. This composite composition provides both magnetic properties to enhance coil performance and sufficient electrical insulation to prevent breakdown, even at reduced intervals between coils.
3Loss of energy
If Litz wire is used to reduce skin effect and improve transmission efficiency, then transmission efficiency is improved, but manufacturing cost and time increase significantly
Solution Approach 1:
The invention replaces expensive Litz wire with a simpler, more cost-effective planar coil structure made from plate material. While Litz wire provides good skin effect mitigation, the planar coil design achieves acceptable performance at significantly lower manufacturing cost and complexity, suitable for large-scale production.
Solution Approach 2:
The invention substitutes the complex three-dimensional Litz wire structure with a two-dimensional planar coil configuration. This mechanical simplification replaces the intricate twisted strand structure with a flat spiral pattern, dramatically reducing manufacturing complexity while maintaining functional 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
The design effectively maintains insulation and performance between stacked planar coils, preventing dielectric breakdown and short circuits while reducing manufacturing complexity and costs.
Implementation Method 1
in the case where the interval described above is filled with a magnetic material, the coil performance can be further improved
Implementation Method 2
a decrease in the interval described above makes dielectric breakdown or a short circuit likely to occur between the planar coils that face each other
Data Source
AI summary
A coil component includes a first planar coil, a second planar coil that is stacked with the first planar coil at an interval, and a spacer member that includes a third layer that fills the interval. As for the coil component, a volume resistivity value of the third layer with respect to an electric current that flows in a direction in which the first planar coil and the second planar coil overlap changes depending on a position of the third layer on a rectangular coordinate system that is determined on a plane perpendicular to the direction in which the first planar coil and the second planar coil overlap.