Stamped Coil Assembly for Wireless Charging
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Solution Overview
Problem
Existing wireless chargers face challenges with high resistance loss in coil patterns due to limited thickness or width, and difficulties in leading terminals outside the coil, increasing manufacturing costs when forming multiple coil patterns on a single substrate.
Innovation Solution
A coil assembly featuring stamped coils with a double-layer structure and a connection substrate that extends both ends of the coils, allowing for efficient insulation and electrical connection, using a flexible printed circuit board or film substrate to connect the coils and reduce resistance loss.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If a circuit pattern forming method is used to form a coil pattern on a substrate, then the coil pattern can be formed on the substrate, but the thickness or width of the coil pattern is limited, resulting in excessively high resistance loss
Solution Approach 1:
The patent transitions from planar circuit patterns to three-dimensional stamped coils with increased thickness. The stamped coils are formed by stamping metal plates and folding them into coil shapes, allowing the coil thickness to exceed the limitations of conventional circuit pattern thickness, thereby reducing resistance loss while maintaining manufacturability
Solution Approach 2:
The patent changes the physical parameters of the coil by using stamped metal coils with adjustable thickness and width parameters. By controlling the stamping process and metal plate dimensions, the coil can achieve optimal thickness and width values that minimize resistance loss, overcoming the fixed parameter constraints of circuit pattern methods
2Productivity
If a plurality of coil patterns are formed on a single substrate, then more coils can be integrated, but it becomes difficult to lead terminals to the outside of the coil, increasing manufacturing cost
Solution Approach 1:
The patent uses a three-dimensional stamped coil structure that naturally provides terminal access. The stamped coils are formed with open ends that can be directly connected to connection substrates, eliminating the need for complex terminal routing through multiple planar layers. This dimensional transition simplifies terminal leading while maintaining high coil integration density
Solution Approach 2:
The patent divides the coil structure into modular stamped units that can be independently formed and then assembled. Each stamped coil unit has its terminals accessible at the ends, allowing straightforward connection to the connection substrate. This segmentation approach enables multiple coils to be integrated without complicating terminal routing, as each module self-contained its terminal access
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 significantly reduces resistance loss and improves manufacturing efficiency by allowing for thicker coils with reduced thickness, enabling effective wireless charging with minimized production costs.
Implementation Method 1
Most wireless chargers transmit and receive power using electromagnetic induction or resonance
Data Source
AI summary
A coil assembly includes a coil part including stamped coils, and a connection substrate having one end thereof disposed inside the coil part and the other end disposed outside the coil part, wherein one end of each of the stamped coils is connected to a first surface of the connection substrate and the other end connected to a second surface of the connection substrate.