Wireless Power Coil with Integrated Magnetic Portion

The patent transitions from a planar multi-layered coil structure to a three-dimensional helical structure. The wire is wound in a spiral pattern around a mandrel, creating a helical geometry that provides both electrical connectivity and structural integrity without requiring multiple stacked layers. This dimensional change allows the coil to achieve the necessary electrical pathways while reducing overall thickness.

The coil structure embeds the electrical connection pathways within the helical winding itself. The inner and outer ends of the coil are naturally formed as part of the helical structure, eliminating the need for separate connection layers. The mandrel serves as a temporary form that is removed after winding, leaving a self-contained helical coil with integrated electrical pathways.

The patent extracts the electrical connection function from separate via-hole and bonding processes and integrates it directly into the coil winding structure. The helical winding naturally creates the necessary electrical pathways, eliminating the need for additional via-hole formation and bonding steps that would increase manufacturing cost and complexity.

The patent combines the coil formation and electrical connection creation into a single winding process. The helical structure simultaneously provides the magnetic field generation capability and the electrical connection pathways, merging multiple functions into one integrated structure rather than requiring separate manufacturing steps for each function.

The helical coil structure is self-containing and self-connecting. The winding process naturally creates both the active coil segments and the connection pathways within the same structure. The inner and outer ends are formed as integral parts of the helix, eliminating the need for external wiring or bonding processes to establish electrical connections.

The coil is segmented into multiple helical turns, where each turn contributes to the magnetic field generation. The connection pathways are segmented along the helical path, with the wire continuously winding from the inner end through multiple turns to the outer end, creating natural segmentation that eliminates the need for separate connection components.