WINGED COIL STRUCTURE AND METHOD OF MANUFACTURING THE SAME

• US 20170103844A1
• Filed: 10/08/2015
• Published: 04/13/2017
• Est. Priority Date: 10/08/2015
• Status: Active Grant

• Current Assignee: Kinsus Interconnect Technology Corporation
• Original Assignee: Kinsus Interconnect Technology Corporation
• Inventors: Lin, Ting-Hao, Chang, Chiao-Cheng, Lin, Yi-Nong
• Granted Patent: US 9,847,165 B2
• Time in Patent Office: Days
• CPC Class Codes: H01F 2027/2809 on stacked layers
• CPC Class Codes: H01F 27/2804 Printed windings
• CPC Class Codes: H01F 41/041 Printed circuit coils apparatus or processes for manufacturing printed circuits in general H05K3/00
• CPC Class Codes: H05K 1/00 Printed circuits
• CPC Class Codes: H05K 1/165 incorporating printed inductors
• CPC Class Codes: H05K 2201/09063 Holes or slots in insulating substrate not used for electrical connections
• CPC Class Codes: H05K 3/00 Apparatus or processes for manufacturing printed circuits
• CPC Class Codes: H05K 3/4635 laminating flexible circuit boards using additional insulating adhesive materials between the boards

Abstract

A winged coil structure and a method of manufacturing the same are disclosed. The winged coil structure includes an upper flexible plate, at least one upper magnetic induction coil, at least one upper connection pad, a lower flexible plate, at least one lower magnetic induction coil, at least one lower connection pad, at least one gold finger, a dielectric layer and at least one connection plug. The connection plug connects the upper connection pad and the lower connection pad through thermal pressing such that the gold finger, the upper magnetic induction coil, the upper connection pad, the lower connection pad, the connection plug, the lower connection pad and the lower magnetic induction coil are electrically connected. The upper flexible plate is provided with notched lines to be easily bent without damage to the upper and lower magnetic induction coils. Thus, a bendable feature for magnetic induction coils is provided.

Claims

1. A winged coil structure for providing a function of magnetic induction and a flexible and bendable feature, and having a wing shape with two thinner side parts than a middle part downwards projecting, comprising:

an upper flexible plate formed of a flexible substrate with electrical insulation, having a middle region and two side regions bordering the middle region, the middle region having a middle through-hole;

at least one upper magnetic induction coil embedded in the upper flexible plate and having a helical shape close to an upper surface of the upper flexible plate;

at least one upper connection pad electrically connected with the corresponding upper magnetic induction coil;

a lower flexible plate formed of an another flexible substrate with electrical insulation, having a middle region and two side regions bordering the middle region, the middle region having a middle through-hole, a lateral size of the lower flexible plate smaller than a lateral size of the upper flexible plate;

at least one lower magnetic induction coil embedded in the lower flexible plate and having a helical shape close to a lower surface of the lower flexible plate;

at least one lower connection pad electrically connected with the corresponding lower magnetic induction coil, and vertically aligned to the corresponding upper connection pad;

at least one gold finger configured at the side regions of the upper flexible plate, and electrically connected with the corresponding lower magnetic induction coil;

a dielectric layer provided between the upper flexible plate and the lower flexible plate, the upper flexible plate being on an upper surface of the dielectric layer, the lower flexible plate beneath a lower surface of the dielectric layer, the dielectric layer having at least one through-hole, each through-hole being aligned to the corresponding upper connection pad and lower connection pad; and

at least one connection plug formed of an electrically conductive metal material, each connection plug penetrating the dielectric layer and provided between the corresponding upper connection pad and lower connection pad, the connection plug possessing workability of thermal pressing so as to tightly combine the upper connection pad and the lower connection pad through thermal pressing,

wherein the upper magnetic induction coil and the lower magnetic induction coil are configured around the middle through-holes of the upper flexible plate and the lower flexible plate, respectively, and separated by the dielectric layer, a notched line is provided along each adjacency of the lower surface of the upper flexible plate and the lower flexible plate, the notched line has a trench recessing upwards or inwards such that the two side regions of the upper flexible plate are bendable upwards or downwards, and the dielectric layer is not extended to the notched line.

2. The winged coil structure as claimed in claim 1, wherein the upper flexible plate and the lower flexible plate are formed of a resin or plastic material, the connection plug is formed of copper, tin, copper alloy or tin alloy, and has a shape of ball, column or block.

3. The winged coil structure as claimed in claim 1, wherein the upper magnetic induction coil, the upper connection pad, the lower magnetic induction coil, the lower connection pad and the gold finger are formed of the same or different electrical conductive material, the electrical conductive material comprises copper, copper alloy or gold, and the dielectric layer is formed of a dielectric material.

4. The winged coil structure as claimed in claim 1, wherein base surfaces of the two side regions of the upper flexible plate are attached to or covered by an external dielectric layer, the external dielectric layer is formed of a dielectric material the same as or different from the dielectric material of the dielectric layer.

5. The winged coil structure as claimed in claim 1, further comprising a covering layer, wherein the covering layer is configured to cover the upper surface of the upper flexible plate, the lower surface of the lower flexible plate, and a surrounding area of the gold finger, and the covering layer is formed of an electrical insulation material with transparency or opaqueness.

6. A winged coil structure for providing a function of magnetic induction and a flexible and bendable feature, and having a wing shape with two thinner side parts than a middle part downwards projecting, comprising:

an upper flexible plate formed of a flexible substrate with electrical insulation, having a middle region and two side regions bordering the middle region, the middle region having a middle through-hole;

at least one upper magnetic induction coil embedded in the upper flexible plate and having a helical shape close to an upper surface of the upper flexible plate;

at least one upper connection pad electrically connected with the corresponding upper magnetic induction coil;

a lower flexible plate formed of an another flexible substrate with electrical insulation, having a middle region and two side regions bordering the middle region, the middle region having a middle through-hole, a lateral size of the lower flexible plate smaller than a lateral size of the upper flexible plate;

at least one lower magnetic induction coil embedded in the lower flexible plate and having a helical shape close to a lower surface of the lower flexible plate;

at least one lower connection pad electrically connected with the corresponding lower magnetic induction coil, and vertically aligned to the corresponding upper connection pad;

at least one gold finger configured at the side regions of the upper flexible plate, and electrically connected with the corresponding lower magnetic induction coil;

a dielectric layer provided between the upper flexible plate and the lower flexible plate, the upper flexible plate being on an upper surface of the dielectric layer, the lower flexible plate beneath a lower surface of the dielectric layer, the dielectric layer having at least one through-hole, each through-hole being aligned to the corresponding upper connection pad and lower connection pad;

at least one connection plug formed of an electrically conductive metal material, each connection plug penetrating the dielectric layer and provided between the corresponding upper connection pad and lower connection pad , the connection plug possessing workability of thermal pressing so as to tightly combine tightly combine the upper connection pad and the lower connection pad through thermal pressing;

a bottom flexible plate formed of a yet flexible substrate with electrical insulation, having a middle region and two side regions bordering the middle region, the middle region having a middle through-hole, a lateral size of the bottom flexible plate smaller identical to a lateral size of the lower flexible plate;

at least one bottom magnetic induction coil embedded in the bottom flexible plate and having a helical shape close to a lower surface of the bottom flexible plate; and

at least one bottom connection pad electrically connected with the corresponding bottom magnetic induction coil, and vertically aligned to the corresponding lower connection pad,

wherein the upper magnetic induction coil, the lower magnetic induction coil and the bottom magnetic induction coil are configured around the middle through-holes of the upper flexible plate, the lower flexible plate and the bottom flexible plate, respectively, and the upper magnetic induction coil and the lower magnetic induction coil are separated by the dielectric layer, a notched line is provided along each adjacency of the lower surface of the upper flexible plate and the lower flexible plate, the notched line has a trench recessing upwards or inwards such that the two side regions of the upper flexible plate are bendable upwards or downwards, and the dielectric layer is not extended to the notched line.

7. The winged coil structure as claimed in claim 6, wherein the upper flexible plate, the lower flexible plate and the bottom flexible plate are formed of a resin or plastic material, the connection plug is formed of copper, tin, copper alloy or tin alloy, and has a shape of ball, column or block.

8. The winged coil structure as claimed in claim 6, wherein the upper magnetic induction coil, the upper connection pad, the lower magnetic induction coil, the lower connection pad, the bottom magnetic induction coil, the bottom connection pad and the gold finger are formed of the same or different electrical conductive material, the electrical conductive material comprises copper, copper alloy or gold, and the dielectric layer is formed of a dielectric material.

9. The winged coil structure as claimed in claim 6, wherein base surfaces of the two side regions of the upper flexible plate are attached to or covered by an external dielectric layer, the external dielectric layer is formed of a dielectric material the same as or different from the dielectric material of the dielectric layer.

10. The winged coil structure as claimed in claim 6, further comprising a covering layer, wherein the covering layer is configured to cover the upper surface of the upper flexible plate, the lower surface of the bottom flexible plate, and a surrounding area of the gold finger, and the covering layer is formed of an electrical insulation material with transparency or opaqueness.

11. A method of manufacturing a winged coil structure for providing a function of magnetic induction and a flexible and bendable feature, comprising:

preparing an upper flexible plate having a middle region and two side regions bordering the middle region, and provided with at least one upper magnetic induction coil, at least one upper connection pad, at least one gold finger and at least one connection plug, the upper flexible plate having a middle through-hole at the middle region, the upper magnetic induction coil and the upper connection pad being electrically connected and embedded in the middle region of the upper flexible plate and close to an upper surface of the upper flexible plate, the at least one gold finger being provided on lower surfaces of the two side regions of the upper flexible plate, each connection plug being provided on the lower surface of the middle region of the upper flexible plate and attached to a bottom of the corresponding upper connection pad;

preparing a dielectric layer with a lateral size the same as a lateral size of the middle region of the upper flexible plate, at least one through-hole being provided at a middle region of the dielectric layer;

preparing a lower flexible plate having a middle region and two side regions bordering the middle region, and provided with at least one lower magnetic induction coil and at least one lower connection pad, the lower flexible plate having a middle through-hole at the middle region, the lower magnetic induction coil and the lower connection pad being electrically connected and embedded in the middle region of the lower flexible plate and close to an lower surface of the lower flexible plate; and

performing a process of thermal pressing to sequentially from bottom to top stack and combine the lower flexible plate, the dielectric layer and the upper flexible plate as a multiple layered stack structure via a press mold, the respective middle through-holes of the lower flexible plate, the dielectric layer and the upper flexible plate being vertically aligned, each connection plug being formed of an electrically conductive metal material with workability of thermal pressing, and configured to penetrate the middle through-hole of the dielectric layer, and provided between the corresponding upper and lower connection pads such that the at least one connection plug tightly combines the corresponding upper and lower connection pads after the process of thermal pressing to form electrical connection,

wherein a notched line is provided along each adjacency of the lower surface of the upper flexible plate and the lower flexible plate, the notched line has a trench recessing upwards or inwards such that the two side regions of the upper flexible plate are bendable upwards or downwards, and the dielectric layer is not extended to the notched line.

12. The method as claimed in claim 11, wherein the upper flexible plate and the lower flexible plate are formed of a resin or plastic material, the connection plug is formed of copper, tin, copper alloy or tin alloy, and has a shape of ball, column or block.

13. The method as claimed in claim 11, wherein the upper magnetic induction coil, the upper connection pad, the lower magnetic induction coil, the lower connection pad and the gold finger are formed of the same or different electrical conductive material, the electrical conductive material comprises copper, copper alloy or gold, and the dielectric layer is formed of a dielectric material.

14. The method as claimed in claim 11, wherein base surfaces of the two side regions of the upper flexible plate are attached to or covered by an external dielectric layer, the external dielectric layer is formed of a dielectric material the same as or different from the dielectric material of the dielectric layer.

15. The method as claimed in claim 11, further comprising a covering layer, wherein the covering layer is configured to cover the upper surface of the upper flexible plate, the lower surface of the lower flexible plate, and a surrounding area of the gold finger, and the covering layer is formed of an electrical insulation material with transparency or opaqueness.

16. A method of manufacturing a winged coil structure for providing a function of magnetic induction and a flexible and bendable feature, comprising:

preparing an upper flexible plate having a middle region and two side regions bordering the middle region, and provided with at least one upper magnetic induction coil, at least one upper connection pad, at least one gold finger and at least one connection plug, the upper flexible plate having a middle through-hole at the middle region, the upper magnetic induction coil and the upper connection pad being electrically connected and embedded in the middle region of the upper flexible plate and close to an upper surface of the upper flexible plate, the at least one gold finger being provided on lower surfaces of the two side regions of the upper flexible plate, each connection plug being provided on the lower surface of the middle region of the upper flexible plate and attached to a bottom of the corresponding upper connection pad;

preparing a dielectric layer with a lateral size the same of a lateral size of the middle region of the upper flexible plate, at least one through-hole being provided at a middle region of the dielectric layer;

preparing a lower flexible plate having a middle region and two side regions bordering the middle region, and provided with at least one lower magnetic induction coil and at least one lower connection pad, the lower flexible plate having a middle through-hole at the middle region, the lower magnetic induction coil and the lower connection pad being electrically connected and embedded in the middle region of the lower flexible plate and close to an lower surface of the lower flexible plate;

preparing a bottom flexible plate attached to the lower surface of the lower flexible plate to form a stack body, having a middle region and two side regions bordering the middle region, and provided with at least one bottom magnetic induction coil and at least one bottom connection pad, the bottom magnetic induction coil and the bottom connection pad being electrically connected, embedded in the middle region of the bottom flexible plate, and close to a lower surface of the bottom flexible plate; and

performing a process of thermal pressing to sequentially from bottom to top stack and combine the stack body, the dielectric layer and the upper flexible plate as a multiple layered stack structure via a press mold, the respective middle through-holes of the bottom flexible plate, the lower flexible plate, the dielectric layer and the upper flexible plate being vertically aligned, each connection plug being formed of an electrically conductive metal material with workability of thermal pressing, and configured to penetrate the middle through-hole of the dielectric layer, and provided between the corresponding upper and lower connection pads such that the at least one connection plug tightly combines the corresponding upper and lower connection pads after the process of thermal pressing to form electrical connection,

wherein a notched line is provided along each adjacency of the lower surface of the upper flexible plate and the lower flexible plate, the notched line has a trench recessing upwards or inwards such that the two side regions of the upper flexible plate are bendable upwards or downwards, and the dielectric layer is not extended to the notched line.

17. The method as claimed in claim 16, wherein the upper flexible plate, the lower flexible plate and the bottom flexible plate are formed of a resin or plastic material, the connection plug is formed of copper, tin, copper alloy or tin alloy, and has a shape of ball, column or block.

18. The method as claimed in claim 16, wherein the upper magnetic induction coil, the upper connection pad, the lower magnetic induction coil, the lower connection pad, the bottom magnetic induction coil, the bottom connection pad and the gold finger are formed of the same or different electrical conductive material, the electrical conductive material comprises copper, copper alloy or gold, and the dielectric layer is formed of a dielectric material.

19. The method as claimed in claim 16, wherein base surfaces of the two side regions of the upper flexible plate are attached to or covered by an external dielectric layer, the external dielectric layer is formed of a dielectric material the same as or different from the dielectric material of the dielectric layer.

20. The method as claimed in claim 16, further comprising a covering layer, wherein the covering layer is configured to cover the upper surface of the upper flexible plate, the lower surface of the bottom flexible plate, and a surrounding area of the gold finger, and the covering layer is formed of an electrical insulation material with transparency or opaqueness.