Vertically Stacked Coil Device for Wireless Power Transfer
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Solution Overview
Problem
Wireless power transfer systems face challenges with coil design, where increased resistance due to thinner coils for more windings reduces charging efficiency, and exposed connecting terminals are prone to contamination and short-circuits, leading to connection failures.
Innovation Solution
A coil device with self-bonded wires stacked vertically on a substrate, increasing inductance and decreasing resistance, allowing for a higher quality factor and more efficient power transfer, while also being designed to minimize mounting area and prevent external contamination.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the coil is made thinner to increase the number of windings, then the number of windings increases, but the resistance of the coil increases and charging efficiency decreases
Solution Approach 1:
The patent transitions from a planar coil structure to a three-dimensional vertically stacked structure. Multiple coil windings are arranged in the vertical direction (z-axis) rather than only in the horizontal plane, allowing increased number of windings without proportionally increasing resistance by utilizing spatial dimensionality change.
Solution Approach 2:
The patent implements nested coil structures where multiple coils are vertically stacked and integrated within a compact space. The coils are arranged in a nested configuration along the vertical direction, maximizing the number of windings within the available volume while maintaining efficient current paths.
2Productivity
If the coil becomes thinner to increase windings, then the number of windings increases, but the resistance increases and quality factor decreases
Solution Approach 1:
By arranging coils in the vertical dimension rather than only horizontally, the patent achieves higher winding counts without the resistance penalties associated with thin planar coils, thereby maintaining quality factor while increasing productivity.
Solution Approach 2:
The patent optimizes geometric parameters of the vertically stacked coil structure, including wire diameter, stacking height, and spacing between windings, to achieve the optimal balance between resistance and inductance for maximizing quality factor.
3Ease of operation
If connecting terminals are exposed for charging connection, then charging functionality is enabled, but the terminals are prone to contamination and short-circuits
Solution Approach 1:
The patent extracts the connection function from exposed external terminals and integrates it into the wireless power transfer coil structure itself. The coil serves dual purposes: power transfer and charging connection, eliminating the need for separate exposed terminals that are susceptible to contamination.
Solution Approach 2:
The wireless electromagnetic field acts as an intermediary medium for power transfer, replacing direct physical contact through exposed terminals. This intermediary mechanism enables charging functionality while preventing contamination and short-circuit issues associated with exposed electrical contacts.
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 enhances charging efficiency by increasing the quality factor and reducing resistance, while also protecting against environmental contaminants, thus improving the reliability and performance of wireless power transfer systems.
Implementation Method 1
The magnetic induction scheme is a non-contact energy transfer technology in which, when two coils approach each other, an electromotive force is generated in the other coil by the medium of magnetic flux generated as current flows in one coil
Implementation Method 2
The magnetic resonance scheme is a magnetic resonance technology using only electric or magnetic fields without using electromagnetic waves or current
Data Source
AI summary
There are provided a coil device, a method for manufacturing the coil, and a wireless power transfer system-charger or a wireless power transfer system-device, which includes the coil device. A coil device includes: a substrate including first and second terminals; and a first coil disposed on one surface of the substrate, the first coil being disposed while turning at least once, wherein the first coil includes a plurality of wires self-bonded to be stacked on the substrate, wherein one sides of the plurality of wires are commonly connected to the first terminal, and the other sides of the plurality of wires are commonly connected to the second terminal.