Wireless Charging Coil Punching Process for Gap Control
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Solution Overview
Problem
Current methods for manufacturing wireless charging coils, such as winding and photo etching, face issues with maintaining consistent gap widths between coil segments, leading to potential short circuits and high production costs, environmental pollution, and thick coil thickness unsuitable for portable devices.
Innovation Solution
A punching process that forms a coil structure with a fixing element to maintain gap width, involving a first punching to create a punched metal piece with a coil structure and a second punching to remove parts of the fixing element, using a transferring film or UV curable adhesive to secure the gap width during the process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the winding method is used to manufacture wireless charging coils, then the gap width between coil segments can be kept consistent, but the overall thickness of the coil becomes too thick for portable electronic devices
Solution Approach 1:
The coil is divided into multiple thin metal pieces that are stacked and bonded together to form the final coil structure. Each metal piece contains coil segments with gaps, and when stacked, these gaps align to create the complete coil pattern. This segmentation allows the coil to achieve the required gap precision while maintaining a thin overall profile, as each individual layer contributes only a small thickness.
Solution Approach 2:
The manufacturing approach transitions from a single-layer thick coil to a multi-layer stacked structure. By distributing the coil pattern across multiple thin layers in the vertical dimension, the solution maintains precise gap control in the horizontal plane while reducing the overall thickness in the vertical direction, making it suitable for portable devices.
2Manufacturing precision
If the photo etching method is used to manufacture wireless charging coils, then the gap width between coil segments can be kept consistent, but the production cost increases and causes environmental pollution
Solution Approach 1:
The patent replaces the chemical photo etching process with a mechanical punching process. Instead of using chemicals to etch away material and create the coil pattern, metal pieces are punched with precise gap patterns using mechanical means. This substitution eliminates the harmful chemical waste associated with photo etching while maintaining consistent gap widths, thereby reducing environmental pollution.
Solution Approach 2:
The punching method uses simple, inexpensive metal pieces that can be quickly manufactured and discarded if defective, replacing the expensive and time-consuming photo etching process. The punching process is faster, reduces production costs, and avoids the environmental pollution generated by chemical etchants and solvents used in photo etching.
3Manufacturing precision
If the photo etching method is used to manufacture wireless charging coils, then the gap width between coil segments can be kept consistent, but the production time increases and electric consumption is high
Solution Approach 1:
The patent replaces the slow, multi-step photo etching process with a rapid mechanical punching operation. The punching process can create multiple metal pieces with precise gap patterns simultaneously or in quick succession, dramatically increasing production speed. This mechanical approach eliminates the sequential steps of coating, exposing, developing, and etching required in photo etching, thereby improving productivity while maintaining gap consistency.
Solution Approach 2:
The punching process allows for continuous production where metal pieces are punched, stacked, and bonded in an uninterrupted flow. This eliminates the idle time between steps inherent in photo etching, maintaining continuous useful action throughout the manufacturing process and significantly improving production efficiency and speed.
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 method ensures consistent gap widths, maintaining coil quality, reducing production costs, and minimizing environmental impact while allowing for thinner, more conductive coils suitable for portable devices with improved efficiency and lower power consumption.
Implementation Method 1
punching a metal piece for forming a coil structure and a fixing element, wherein the coiling structure comprises a plurality of coil segments, a gap is defined by two of the plurality of coil segments, and the fixing element connects to the two coil segments for keeping a width of the gap
Implementation Method 2
Pasting a transferring film on the punched metal piece, wherein the transferring film connects to the two coil segments for keeping the width of the first gap
Data Source
AI summary
A punching process for wireless charging coils comprises: punching a metal piece for forming a coil structure and a fixing element, the coiling structure having a plurality of coil segments, a gap being between two of the plurality of coil segments, and the fixing element connecting the coil segments for keeping the width of the gap.