3D shaped inductive charging coil and method of making the same

• US 10,211,663 B2
• Filed: 03/28/2016
• Issued: 02/19/2019
• Est. Priority Date: 08/21/2015
• Status: Active Grant

• Current Assignee: Apple Inc.
• Original Assignee: Apple Inc.
• Inventors: Matsuyuki, Naoto, Graham, Christopher S., Brzezinski, Makiko K.
• Primary Examiner(s): Rossoshek, Helen
• Application Number:
  US15/082,935
• Publication Number:
  US 20170054318A1
• Time in Patent Office: 1,058 Days
• CPC Class Codes: H01F 2027/2809 on stacked layers
• CPC Class Codes: H01F 27/2871 Pancake coils
• CPC Class Codes: H01F 27/327 Encapsulating or impregnating encapsulating coil and core H01F27/022
• CPC Class Codes: H01F 38/14 Inductive couplings for wireless supply or distribution of electric power using inductive coupling H02J50/10
• CPC Class Codes: H01F 41/127 Encapsulating or impregnating encapsulating coil and core H01F41/005
• CPC Class Codes: H01L 23/5226 Via connections in a multilevel interconnection structure
• CPC Class Codes: H01L 23/5227 Inductive arrangements or effects of, or between, wiring layers other inductive arrangements H01L23/645
• CPC Class Codes: H02J 50/005 Mechanical details of housing or structure aiming to accommodate the power transfer means, e.g. mechanical integration of coils, antennas or transducers into emitting or receiving devices
• CPC Class Codes: H02J 50/10 using inductive coupling

Abstract

A three-dimensional inductive charging coil assembly and a method of making the same. The method can include patterning a first conductive layer affixed to a first surface of an insulating layer to form a coil configured to transmit or receive power, patterning a second conductive layer affixed to a second surface of the insulating layer opposite the first surface to form a conductive trace element, and electrically coupling the coil and the conductive trace element. The coil, insulating layer, and conductive trace element can be molded (e.g., simultaneously) into a three dimensional shape. In some embodiment, the molding can include a thermoforming process such as compression molding, vacuum forming, or the like.

Claims

1. An inductive charging component for wireless charging comprising:

a curved charging surface;

an inductive coil assembly proximate the curved charging surface, the inductive coil assembly comprising;

an insulating layer comprising a first surface and a second surface opposite the first surface;

a conductive multi-turn coil arranged in a spiral pattern on the first surface of the insulating layer; and

a conductive trace element affixed to the second surface of the insulating layer, wherein the conductive multi-turn coil and the conductive trace element are electrically coupled, the conductive multi-turn coil, the conductive trace element and the insulating layer having a curvature corresponding to the curved charging surface.

2. The inductive charging component of claim 1 wherein the conductive multi-turn coil, the insulating layer, and the conductive trace element have a non-planar geometry.

3. The inductive charging component of claim 1 wherein the conductive multi-turn coil and the conductive trace element are electrically coupled by a via formed through the insulating layer.

4. The inductive charging component of claim 2 further comprising a laminate layer disposed on the multi-turn coil, wherein the laminate layer has a non-planar geometry.

5. An inductive charging component comprising:

a curved charging surface; and

an inductive coil assembly adjacent to the curved charging surface, wherein the inductive coil assembly comprises;

a polymer layer comprising a first surface and a second surface opposite the first surface, the polymer layer having a curvature corresponding to the curved charging surface;

a multi-turn coil coupled to the first surface of the polymer layer and configured to transmit or receive power;

a conductive trace element adhesive coupled to the second surface of the polymer layer; and

a via formed through the polymer layer that electrically couples the multi-turn coil and the conductive trace element.

6. The inductive charging component of claim 5 wherein the polymer layer is non-planar, and wherein the inductive coil assembly is characterized by a three-dimensional shape such that it conforms to a contour of the curved charging surface.

7. The inductive charging component of claim 5 wherein the inductive coil assembly further comprises:

a laminate layer disposed on the multi-turn coil.

8. The inductive charging component of claim 5 wherein the inductive coil assembly further comprises:

a ferrite layer disposed on the conductive trace element.

9. The inductive charging component of claim 5, wherein the multi-turn coil is formed by patterning a metal layer affixed to the first surface of the polymer layer.