Wireless Charging Coil Integration in Interconnect Structures
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Solution Overview
Problem
Current wireless charging technologies face challenges in efficiently integrating wireless charging coils with highly integrated components and scaling down for small applications like wearable devices, while maintaining effective charging efficiency and portability.
Innovation Solution
The integration of wireless charging coils within structures that include highly integrated components, formed in the same material layer as through-vias and interconnect structures, with a controller embedded in a molding compound, allowing for adjustable electrical characteristics and compact design.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If wireless charging coils are integrated with highly integrated components in the same material layer, then device complexity is reduced and manufacturing efficiency is improved, but manufacturing precision requirements increase due to the need to form coils and through-vias simultaneously
Solution Approach 1:
The patent merges the wireless charging coil formation process with the through-via formation process by forming both structures simultaneously from the same conductive material layer. This integration reduces the number of separate manufacturing steps and eliminates the need for separate coil assembly, thereby reducing device complexity while maintaining manufacturing precision through a unified formation process.
2Volume of moving object
If wireless charging coils are scaled down for small applications like wearable devices, then portability and adaptability are improved, but charging efficiency deteriorates due to reduced coil size and inductance
Solution Approach 1:
The patent applies local quality by creating regions of high magnetic field concentration within the scaled-down coil structure. By optimizing the local magnetic path and using high-permeability materials in specific areas, the design maintains effective charging efficiency despite the overall reduced size, enabling portable wireless charging for wearable devices.
Solution Approach 2:
The patent uses composite materials combining conductive layers with high-permeability magnetic materials to enhance the inductance density of the scaled-down coil. This composite structure allows the miniaturized wireless charging coil to maintain sufficient magnetic coupling and charging efficiency while achieving the compact form factor required for wearable applications.
3Ease of manufacture
If wireless charging coils are formed in the same material layer as through-vias, then ease of manufacture is improved by reducing assembly steps, but device complexity increases due to the need for multi-functional material layers
Solution Approach 1:
The patent implements universality by designing the conductive material layer to serve multiple functions: forming both the wireless charging coil windings and the through-vias that provide electrical interconnections. This multi-functional layer eliminates the need for separate coil windings and via formation steps, significantly easing manufacturing while the added design flexibility compensates for the initial complexity of creating a multi-functional material structure.
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 enables efficient wireless charging with adjustable resistance, inductance, and Q-factor, suitable for small applications like wearable devices, while ensuring high integration and portability.
Implementation Method 1
Wireless charging is a technology in which an electromagnetic field is used to transfer energy between two objects. The transfer of the energy using the electromagnetic field is usually accomplished with a charging station. The energy is transferred through an inductive coupling with an electronic device.
Implementation Method 2
The controller is adapted to control an operation of the wireless charging coil. The wireless charging devices are adapted to provide an inductance to charge an electronic device using inductive charging and/or resonance charging.
Data Source
AI summary
Wireless charging devices, methods of manufacture thereof, and methods of charging electronic devices are disclosed. In some embodiments, a wireless charging device includes a controller, a molding material disposed around the controller, and an interconnect structure disposed over the molding material and coupled to the controller. The wireless charging device includes a wireless charging coil coupled to the controller. The wireless charging coil comprises a first portion disposed in the interconnect structure and a second portion disposed in the molding material. The wireless charging coil is adapted to provide an inductance to charge an electronic device.