Wireless Charging Antenna Arrays with Varying Coil Cross-Sections
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Solution Overview
Problem
Wireless energy transmitters embedded in expansive surfacing materials face inefficiencies due to the Q factor limitations of individual coils, leading to waste in higher Q factor components and increased manufacturing costs, as well as the need for accurate device recognition to prevent power transmission to unintended objects.
Innovation Solution
The use of antenna arrays with conductive traces of varying cross-sectional areas, where outer coils have reduced cross-sectional areas to balance the Q factor among coils, optimizing energy transmission while reducing material usage and manufacturing costs, and incorporating a soft ferrite enhancer material to enhance magnetic permeability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If all coils in the antenna array use the same cross-sectional area, then manufacturing is simplified, but the Q factor is not uniform across the array leading to energy transmission inefficiency
Solution Approach 1:
The patent applies local quality by varying the cross-sectional area of conductive traces at different positions within the antenna array. Specifically, outer coils have reduced cross-sectional areas compared to inner coils, creating localized property variations that balance the Q factor across the entire array. This resolves the contradiction by achieving uniform Q factor performance without requiring all coils to have identical complex structures.
2Productivity
If standard uniform conductive traces are used throughout the antenna array, then manufacturing cost is reduced, but energy transmission efficiency decreases due to Q factor limitations
Solution Approach 1:
The patent implements local quality by selectively reducing the cross-sectional area of conductive traces in outer regions of the antenna array while maintaining standard dimensions in inner regions. This localized modification optimizes energy transmission efficiency across the entire array by balancing Q factor, while the majority of the structure retains simple, easy-to-manufacture uniform characteristics.
Solution Approach 2:
The patent applies parameter changes by modifying the cross-sectional area dimension of conductive traces based on their position within the antenna array. Outer coils utilize reduced cross-sectional area parameters compared to inner coils, creating the necessary Q factor balance for efficient energy transmission while maintaining manufacturing feasibility through controlled parameter variation.
3Loss of substance
If conductive trace cross-sectional area is reduced to save material cost, then material usage decreases, but Q factor performance deteriorates
Solution Approach 1:
The patent applies local quality by strategically reducing conductive material in outer regions where full cross-sectional area is less critical for performance, while maintaining adequate material dimensions in inner regions where Q factor performance is paramount. This localized material optimization achieves cost and resource efficiency without sacrificing overall system reliability.
Solution Approach 2:
The patent implements parameter changes by position-dependent adjustment of conductive trace cross-sectional area. The cross-sectional area parameter is reduced in outer coils to minimize material usage, while inner coils maintain larger cross-sectional areas to ensure sufficient Q factor performance, creating an optimized balance between material efficiency and system reliability.
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 optimizes the Q factor of the antenna array, reduces material usage, and enhances cost-effectiveness by balancing the energy transmission across coils, ensuring efficient wireless charging while maintaining device recognition accuracy.
Implementation Method 1
incorporating a soft ferrite enhancer material to enhance magnetic permeability
Implementation Method 2
An approach to such wireless energy transmission is based on inductive coupling between a transmit antenna embedded in, for example, a 'charging mat' or other surface, and a receiver antenna
Data Source
AI summary
Antenna array comprising: (i) a first conductive trace having a first cross-sectional area; (ii) a second conductive trace having a second cross-sectional area; (iii) an interposing insulating member having a first surface and an opposing second surface; and (iv) wherein the second cross-sectional area is less than the first cross-sectional area. Methods comprising: (i) providing a first insulating member; (ii) patterning a first conductive trace on the first insulating member; (iii) providing a second insulating member; (iv) patterning a second conductive trace on the second insulating member; (v) stacking and compressing the first insulating member, the second insulating member and a third insulating member; and (vi) where the first conductive trace has a cross-sectional area that is greater than a cross-sectional area of the second conductive trace.