Wireless Charging Antenna Structure With Magnetic Flux Shielding
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Solution Overview
Problem
The process of integrating magnetic materials into antenna structures for wireless charging is complex and costly, complicating the manufacturing process and reducing efficiency.
Innovation Solution
An antenna structure is designed with an insulating substrate, a coil wound around an axis, a coating layer with a first magnetic material, and a shielding sheet with a second magnetic material, spaced apart by a critical distance to reduce magnetic flux leakage, using materials like iron, nickel, and nanocrystals on a flexible printed circuit board.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If magnetic material is inserted between patterns of the coil, then wireless charging efficiency is improved, but manufacturing complexity and cost increase
Solution Approach 1:
The patent combines the magnetic material insertion process with the coil winding process by inserting the magnetic material after the coil is wound, rather than between patterns. This merging of operations simplifies the manufacturing process while maintaining the magnetic flux directing function needed for wireless charging efficiency.
Solution Approach 2:
The magnetic material is prepared and positioned in advance before the coil winding is completed. This preliminary action allows the magnetic material to be seamlessly integrated into the antenna structure without requiring complex post-processing or precise alignment during assembly, thereby reducing manufacturing complexity.
2Reliability
If first magnetic material fully covers the coil, then magnetic flux direction is improved, but manufacturing complexity increases
Solution Approach 1:
The first magnetic material is applied selectively to specific regions of the coil rather than fully covering it. This local quality approach directs the magnetic flux where needed for efficient wireless charging while avoiding the complexity of complete coverage, allowing optimization of magnetic field distribution without uniform material application.
Solution Approach 2:
Instead of fully covering the coil with magnetic material, the patent applies partial coverage that is sufficient to achieve the desired magnetic flux direction. This partial action avoids the unnecessary complexity of complete coverage while maintaining the essential function of magnetic flux control for wireless charging.
3Object-affected harmful factors
If shielding sheet is placed close to coil, then magnetic flux shielding is improved, but magnetic flux leakage to coating layer increases
Solution Approach 1:
The patent introduces a spacer as an intermediary element between the shielding sheet and the coil. This spacer mediates the interaction by maintaining an optimal distance that prevents direct contact, thereby reducing magnetic flux leakage to the coating layer while still allowing the shielding sheet to effectively shield harmful magnetic flux from components below.
Solution Approach 2:
The spacer creates an equipotential magnetic field distribution between the shielding sheet and the coil, optimizing the magnetic flux path. By maintaining a specific distance, the magnetic field lines are properly directed through the magnetic materials without short-circuiting to the coating layer, balancing shielding effectiveness with energy efficiency.
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 allows for cost-effective and efficient wireless charging by simplifying the manufacturing process and enhancing charging efficiency through optimized magnetic flux management.
Implementation Method 1
the electronic device may receive power signals from the external device through a coil of the antenna structure
Implementation Method 2
a magnetic material for directing a magnetic flux generated by the coil in the first direction
Implementation Method 3
The second magnetic material may direct a magnetic flux in the first direction, and may also shield another magnetic flux generated in the coil by components of the electronic device disposed below the same
Data Source
AI summary
Provided is an antenna structure configured to wirelessly charge, the antenna structure including an insulating substrate, a coil formed on a first surface of the insulating substrate in a winding structure, the coil being wound a certain number of times in a clockwise and/or a counterclockwise direction around an axis normal to the insulating substrate, a coating layer including a first magnetic material, the coating layer being disposed adjacent to and surrounding the coil in a winding structure corresponding to the winding structure of the coil, and a shielding sheet including a second magnetic material and facing the second surface of the insulating substrate.