Wireless Charging Coil Fixity via Variable Depth Slots
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Solution Overview
Problem
Conventional wireless charging devices have poor coil fixity and difficulty in assembling multiple coils due to the design of slots on the substrate, which restricts the flexibility and efficiency of coil placement.
Innovation Solution
The method involves forming a substrate with slots of varying depths to securely hold coils, allowing for better assembly and modularization, and includes a metal forming process to create spiral coils that can be easily placed and electrically coupled with a power module.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the coil is disposed in a slot of a substrate with uniform depth, then the slot can contain the coil, but the fixity of the coil is poor
Solution Approach 1:
The patent applies local quality by varying the depth of different slots to match the specific requirements of each coil. Each slot is designed with a specific depth corresponding to the coil it contains, providing localized optimization for coil fixity rather than using a uniform slot depth throughout the substrate.
Solution Approach 2:
The patent introduces depth variation as an additional dimension in slot design. Instead of only varying slot width or position, the invention utilizes the depth dimension to enhance coil retention, creating a three-dimensional slot structure that better accommodates and secures the coils.
2Ease of manufacture
If multiple coils are stacked on slots of a substrate, then the wireless charging device can have multiple coils, but the coils cannot be easily assembled since coils cannot be easily bent
Solution Approach 1:
The patent segments the coil assembly process by providing each coil with its own dedicated slot of appropriate depth. This segmentation allows coils to be independently placed and secured without requiring complex bending or interlocking mechanisms, simplifying the overall assembly process while maintaining multi-coil functionality.
Solution Approach 2:
The patent applies preliminary action by pre-designing slots with depths that correspond to the dimensions of the coils before assembly. This pre-planned slot configuration eliminates the need for complex real-time adjustments or bending operations during the assembly process, making coil installation straightforward.
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 enhances coil fixity and reduces manufacturing costs by enabling modular coil assembly and efficient energy transfer in wireless charging devices.
Implementation Method 1
forming a first coil and a second coil by performing a metal forming process on the first metal plate and the second metal plate
Implementation Method 2
Wireless charging, which is also called non-contact inductive charging, transfers energy from a charging device to an electronic device (to be charged) in an inductive coupling method
Data Source
AI summary
A method for manufacturing a wireless charging device is disclosed. The method includes: providing a substrate, a first metal plate, and a second metal plate; forming a plurality of circles of slots, each of the circles of slots including at least one first slot and at least one second slot, the at least one first slot having a first depth, and the at least one second slot having a second depth; forming a first coil and a second coil by performing a metal forming process on the first metal plate and the second metal plate; and placing the first coil in the at least one first slot, and placing the second coil in the at least one second slot. In the method, the first coil and the second coil have good fixity and are easily to be assembled.