Wireless Power Antenna Laser Etch Manufacturing
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Solution Overview
Problem
Current methods for manufacturing wireless power transfer antennas, particularly those using printed circuit boards (PCBs), are limited by the precision of the etching process, which restricts the achievable gap widths and turn widths, thereby limiting the electrical characteristics and efficiency of the antennas.
Innovation Solution
The use of a combination of laser cutting and chemical etching to manufacture wireless power transfer antennas, allowing for tighter gap widths and increased turn widths, thereby enhancing the quality factor (Q) and equivalent series resistance (ESR), and reducing manufacturing time and costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If chemical etching is used to manufacture PCB antennas, then manufacturing efficiency is improved, but gap width precision is limited
Solution Approach 1:
The manufacturing process is segmented into two distinct stages: laser cutting for initial trace formation and chemical etching for gap definition. This segmentation allows each process to optimize for its specific function, with laser providing precision for trace geometry and etching providing efficiency for gap creation, thereby resolving the contradiction between manufacturing efficiency and gap width precision.
Solution Approach 2:
Laser cutting is performed as a preliminary action before chemical etching to pre-defin the trace geometry and create initial gaps. This preliminary structuring of the conductive material allows the subsequent etching process to work from a pre-prepared substrate, improving both the precision of final gap dimensions and the overall manufacturing efficiency by reducing the burden on the etching process.
2Reliability
If smaller gap widths are achieved through etching, then antenna quality factor (Q) is improved, but manufacturing complexity increases
Solution Approach 1:
Two manufacturing processes (laser cutting and chemical etching) are merged into a sequential hybrid process. The laser cutting step creates initial traces and gaps with high precision, while the chemical etching step refines the gap dimensions. This combination achieves smaller, more precise gap widths for improved quality factor without significantly increasing manufacturing complexity, as both processes use standard industrial equipment.
Solution Approach 2:
The traditional purely mechanical/chemical etching process is replaced by introducing laser cutting technology. The laser provides precise, contactless material removal capability that complements the chemical etching process, enabling achievement of smaller gap widths with controlled precision without requiring overly complex etching machinery or multi-step mechanical processes.
3Ease of manufacture
If traditional etching is used for PCB antenna manufacturing, then process simplicity is maintained, but antenna performance is limited
Solution Approach 1:
The manufacturing process is segmented into two distinct stages: laser cutting for initial trace formation and chemical etching for gap definition. This segmentation allows each process to optimize for its specific function, with laser providing precision for trace geometry and etching providing efficiency for gap creation, thereby resolving the contradiction between manufacturing efficiency and gap width precision.
Solution Approach 2:
Laser cutting is performed as a preliminary action before chemical etching to pre-defin the trace geometry and create initial gaps. This preliminary structuring of the conductive material allows the subsequent etching process to work from a pre-prepared substrate, improving both the precision of final gap dimensions and the overall manufacturing efficiency by reducing the burden on the etching process.
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 results in antennas with improved efficiency and performance, particularly at lower operating frequencies, and enables faster, more cost-effective high-volume production while maintaining precision, with gap widths as low as 90-100 microns achieved in experimental results.
Implementation Method 1
laser cutting the first sheet within the coil area, based on a laser cutting path
Implementation Method 2
substantially exposing the first sheet to an etching solution, the etching solution substantially removing first portions of the conductive metal
Implementation Method 3
inductive wireless power transfer, which occurs when magnetic fields created by a transmitting element induce an electric field, and hence, an electric current, in a receiving element
Data Source
AI summary
A method for manufacturing an antenna for a wireless power transfer system includes providing a first sheet of a conductive metal, the first sheet defining a first area for a coil of the antenna. The method includes applying an etch resistant coating on a coil area within the first area and laser cutting the first sheet within the coil area, based on a laser cutting path defining a first geometry for a first plurality of turns for a first layer of the coil, the first geometry configured for one or more of transmission of wireless power signals, receipt of wireless power signals, and combinations thereof. The method further includes substantially exposing the first sheet to an etching solution, the etching solution substantially removing first portions of the conductive metal from the substrate to define, at least, first turn gaps between at least two of the first plurality of turns.