Triple Axis Sensor on Single Layer Printed Circuit
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Solution Overview
Problem
Existing methods for forming coils on printed circuit boards are costly and inefficient, particularly when aiming to create mutually orthogonal coils.
Innovation Solution
A flexible single-sided printed circuit board (PCB) is rolled into a Swiss roll configuration, with conducting elements formed on one side and interconnected by vias, to create a set of three mutually orthogonal coils.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional methods are used to form coils on printed circuit boards, then manufacturing precision and reliability are maintained, but manufacturing cost and device complexity increase significantly
Solution Approach 1:
The patent transitions from planar coil formation to three-dimensional Swiss roll configuration by rolling the PCB substrate. Conducting traces are deposited on a flexible substrate in a flattened state, then the substrate is rolled into a cylindrical configuration where the traces form orthogonal coils in three dimensions. This dimensional transformation enables complex 3D coil structures while maintaining simple planar manufacturing processes.
Solution Approach 2:
The patent employs a flexible PCB substrate that can be rolled into a Swiss roll configuration. The flexibility of the thin film substrate allows it to be bent and rolled without breaking the conducting traces, enabling the transformation from a flat 2D layout to a 3D cylindrical structure that forms orthogonal coils when rolled.
2Manufacturing precision
If multiple layers and complex routing are used to create orthogonal coils, then coil orthogonality is achieved, but manufacturing precision and production time decrease
Solution Approach 1:
Instead of achieving coil orthogonality through complex multi-layer routing on a flat PCB, the patent uses dimensional transformation by rolling. Orthogonal coils are formed naturally in three dimensions when the flat substrate is rolled into a Swiss roll configuration, simplifying the manufacturing process while maintaining precise orthogonality.
Solution Approach 2:
The conducting traces are pre-deposited on the flexible substrate in a specific pattern before rolling. The preliminary layout of traces on the flat substrate is designed so that when rolled, they automatically form orthogonal coils with precise geometric relationships, eliminating the need for complex post-assembly adjustments.
3Ease of manufacture
If conventional coil formation methods are used, then structural stability is maintained, but manufacturing cost and process complexity increase
Solution Approach 1:
The flexible PCB substrate provides structural stability while enabling the Swiss roll configuration. The rigid-flexible combination maintains the integrity of conducting traces during rolling and operation, ensuring stable coil formation without requiring complex assembly processes.
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 significantly reduces the cost and complexity of producing orthogonal coils, enabling efficient formation of sensing coils for magnetic tracking systems.
Implementation Method 1
the first and second lines define a first plane orthogonal to the axis, and the third and fourth lines define a second plane, distinct from the first plane, orthogonal to the axis
Data Source
Figure 1
Figure 2A
Figure 2B
AI summary
Apparatus, including a flexible insulating substrate, having a first side and a second side, rolled about an axis parallel to the substrate. The apparatus also includes a first conducting spiral that is right-handed relative to a normal to the substrate, and a second conducting spiral that is left-handed relative to the normal, formed on the first side of the substrate. The first conducting spiral has a first initial termination and a first final termination, the second conducting spiral has a second initial termination and a second final termination, the spirals have a displacement therebetween, with a preset magnitude so that when the substrate is rolled about the axis the first initial termination aligns with the second initial termination. The apparatus also has a via penetrating the substrate from the first side to the second side so as to interconnect the first initial termination and the second initial termination.