Wireless Coil Assembly With Magnetic Adhesive for Thin Charging Modules
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Solution Overview
Problem
Existing wireless charging and communication modules face challenges in achieving better charging and communication performance while maintaining a thin form factor due to suboptimal coil structures and adhesion methods.
Innovation Solution
A wireless transmission module design featuring a base assembly with magnetically conductive elements and adhesive elements that securely hold the coil in place, enhancing mechanical strength and efficiency, and incorporating structural strengthening portions for improved performance and miniaturization.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a magnetically conductive substrate is used to support the coil, then magnetic field concentration is improved, but device thickness increases
Solution Approach 1:
The base assembly is segmented into multiple functional layers: magnetically conductive elements (powder or particles) dispersed within an adhesive layer, rather than using a solid magnetically conductive substrate. This segmentation allows the magnetic function to be distributed throughout the adhesive layer thickness, maintaining magnetic field concentration while reducing overall module thickness.
Solution Approach 2:
The patent uses thin adhesive layers containing magnetically conductive particles to replace traditional thick magnetically conductive substrates. The adhesive layer acts as a thin film that provides both structural support and magnetic field concentration, significantly reducing the thickness of the wireless transmission module while maintaining charging performance.
2Strength
If traditional adhesion methods are used to secure the coil, then manufacturing simplicity is maintained, but mechanical strength and charging efficiency decrease
Solution Approach 1:
The adhesive layer is formulated as a composite material containing magnetically conductive particles (such as iron powder, silicon chromium alloy, or nanometer-grade particles) dispersed within an adhesive matrix. This composite structure provides both strong adhesion to secure the coil and enhanced magnetic field concentration, improving mechanical strength and charging efficiency simultaneously.
Solution Approach 2:
The patent specifies precise parameter ranges for the adhesive layer, including thickness (5-20 micrometers), melting point (70-400°C), and particle size (50-500 nanometers for nanometer-grade particles). By optimizing these parameters, the adhesive layer achieves optimal balance between coil fixation strength, magnetic field concentration, and manufacturing feasibility.
3Productivity
If coil structure is optimized for better charging performance, then charging efficiency improves, but device complexity increases
Solution Approach 1:
The adhesive layer serves multiple functions simultaneously: it acts as a structural support to hold the coil in place, provides magnetic field concentration through embedded magnetically conductive particles, and facilitates heat dissipation. This multi-functionality improves charging efficiency without requiring additional separate components, thereby avoiding increased device complexity.
Solution Approach 2:
The patent merges the functions of structural support, magnetic field concentration, and thermal management into a single integrated adhesive layer. By combining these functions that would traditionally require separate components, the design achieves high charging efficiency while maintaining simple module structure and avoiding increased device complexity.
4Reliability
If magnetically conductive elements with small diameter are used, then magnetic field concentration improves, but manufacturing precision requirements increase
Solution Approach 1:
The patent specifies precise parameter ranges for magnetically conductive particle sizes, offering multiple options: 50-500 nanometers for nanometer-grade particles, or 1-10 micrometers for finer particles. By defining these specific parameter ranges, the patent balances magnetic field concentration requirements with achievable manufacturing precision, ensuring that the small particle size delivers enhanced magnetic performance while remaining feasible for mass production.
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 improves mechanical strength, charging efficiency, heat dissipation, and reduces electromagnetic interference, enabling overall miniaturization and lightweight construction of wireless transmission modules.
Implementation Method 1
the wireless charging receiving terminal inside the electronic device generates current via electromagnetic induction or electromagnetic resonance
Implementation Method 2
the magnetically conductive substrate can concentrate the magnetic lines of force emitted from the coil for better performance
Implementation Method 3
The first adhesive element is in direct contact with the first magnetically conductive elements. The first adhesive element is in direct contact with the first coil. The first coil is fixedly connected to the first magnetically conductive elements through the first adhesive element
Data Source
AI summary
A wireless transmission module corresponds to an electronic module and is configured to transmit a first signal. The wireless transmission module includes a corresponding surface, a base assembly, and a first coil. The corresponding surface faces the electronic module and is perpendicular to a main axis. The first coil is disposed on the base assembly. The first coil overlaps at least a portion of the base assembly when viewed along the main axis. The first coil overlaps at least a portion of the base assembly when viewed in a direction that is perpendicular to the main axis.