Method for producing a wireless charging coil

• US 10,447,062 B2
• Filed: 04/27/2017
• Issued: 10/15/2019
• Est. Priority Date: 04/28/2016
• Status: Active Grant

• Current Assignee: Cyntec Co. Ltd. (Delta Electronics Incorporated)
• Original Assignee: Cyntec Co. Ltd. (Delta Electronics Incorporated)
• Inventors: Chiu, Kuan-Yu, Hsieh, Hsieh-Shen, Chung, Sheng-Heng, Lu, Chien-Tung
• Primary Examiner(s): Kim, Paul D
• Application Number:
  US15/498,492
• Publication Number:
  US 20170317517A1
• Time in Patent Office: 901 Days
• CPC Class Codes: H01F 27/2823 Wires H01F27/2866 takes precedence
• CPC Class Codes: H01F 27/324 Insulation between coil and core, between different winding sections, around the coil; Other insulation structures
• 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 41/069 Winding two or more wires, e.g. bifilar winding
• CPC Class Codes: H01F 41/094 Tensioning or braking devices
• CPC Class Codes: H01F 5/06 Insulation of windings
• 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 wireless charging coil with a high Q factor includes a plurality of wire groups. Each of the wire groups includes a plurality of wires, a self-bonding film and a plurality of insulation layers. The wires are spun together in a helical manner to form a self-woven structure of the wire group. The self-bonding film surrounds the plurality of wires, and each of the insulation layers covers a surface of a wire. The plurality of wire groups together are wound into a plurality of turns on a same winding surface, and all of the plurality of wire groups are wound on the same winding surface. Each turn is wound by the plurality of wire groups.

Claims

1. A method for producing a wireless charging coil comprising:

providing a plurality of wire groups, each wire group comprising a plurality of wires spun together in a helical manner to form a self-woven structure of the wire group and a self-bonding film surrounding the plurality of wires;

fixing first ends of a plurality of wire groups on an active jig of a winding machine;

engaging the active jig with a passive jig, wherein the active jig and the passive jig have a same spin axis;

winding the plurality of wire groups on a winding surface between the active jig and the passive jig, wherein the winding surface extends outward from the spin axis, and the plurality of wire groups are wound outward from the spin axis on the winding surface; and

disengaging the passive jig from the active jig.

2. The method of claim 1, further comprising adjusting tensions of the plurality of wire groups separately.

3. The method of claim 2, wherein adjusting the tensions of the plurality of wire groups separately comprises adjusting the tensions of the plurality of wire groups by a plurality of tensioners, a plurality of pulleys, or a plurality of damping clamps.

4. The method of claim 1, further comprising:

adjusting a winding speed of the winding machine according to characteristics of a winding shape of the plurality of wire groups;

wherein the winding speed of the winding machine when winding the plurality of wire groups on a vertex of the winding shape is smaller than the winding speed of the winding machine when winding the plurality of wire groups on an smooth edge of the winding shape.

5. The method of claim 1, further comprising bonding the plurality of wire groups before removing the passive jig.

6. The method of claim 5, wherein bonding the plurality of wire groups is performed by hot air bonding, heat resistance bonding and/or solvent bonding the plurality of wires.

7. The method of claim 1, further comprising:

disposing the plurality of wire groups on a winding plate of the active jig in parallel before the winding machine winds the plurality of wire groups;

wherein;

engaging the active jig with the passive jig comprises pressing the passive jig against the active jig while preserving a gap between the winding surface of the winding plate and an engaging surface of the passive jig for containing the plurality of wire groups by a protrusion structure;

the active jig and the passive jig are engaged with a set of engaging structures; and

a diameter of the set of engaging structures is smaller than a diameter of the protrusion structure.

8. The method of claim 7, wherein:

the protrusion structure is extended from a center of the winding plate of the active jig;

the set of engaging structures comprises an opening and a bulge for inserting into the opening when engaging the active jig with the passive jig;

the opening is disposed at a center of the engaging surface and the bulge disposed at a center of the protrusion structure, or the opening is disposed at the center of the protrusion structure and the bulge disposed at the center of the engaging surface; and

a height of the protrusion structure is substantially equal to a diameter of each of the plurality of wire groups.

9. The method of claim 7, wherein:

the protrusion structure is extended from a center of the engaging surface of the passive jig;

the set of engaging structures comprises an opening and a bulge for inserting into the opening when engaging the active jig with the passive jig;

the opening is disposed at a center of the protrusion structure and the bulge disposed at a center of the winding plate, or the opening is disposed at the center of the winding plate and the bulge disposed at the center of the protrusion surface; and

a height of the protrusion structure is substantially equal to a diameter of each of the plurality of wire groups.

10. The method of claim 7, wherein:

the active jig further comprises a wiring slot disposed on the winding surface of the winding plate of the active jig, extending from a center of the winding plate to an periphery of the winding plate, and overlapping with a winding area of the winding surface; and

fixing the first ends of the plurality of wire groups on the active jig of the winding machine is fixing the first ends of the plurality of wire groups at a line hanging structure behind the winding plate through the wiring slot.

11. The method of claim 10, wherein the wiring slot extends from an edge of the protrusion structure near the spin axis to an edge of the winding plate.

12. The method of claim 1, wherein disengaging the passive jig from the active jig comprises making the passive jig and the active jig have different spinning speeds.

13. The method of claim 12, wherein making the passive jig and the active jig have different spinning speeds is performed by spinning one or both of the passive jig and the active jig.

14. The method of claim 1, wherein the passive jig and the active jig have different spinning speeds when the winding machine winds the plurality of wire groups.

15. The method of claim 1, further comprising coupling the first ends of the plurality of wire groups and coupling second ends of the plurality of wire groups, wherein the plurality of wire groups are electrically coupled in parallel.

16. The method of claim 1, wherein the plurality of wire groups are wound together into a plurality of turns on a same winding surface, all of the plurality of wire groups are wound on the same winding surface, and each turn is wound by the plurality of wire groups.

17. The method of claim 1, further comprising:

fixing second ends of the plurality of wire groups on the active jig of the winding machine or tensioners.