WIRELESS CHARGING COIL WITH A HIGH Q FACTOR

• US 20170317517A1
• Filed: 04/27/2017
• Published: 11/02/2017
• 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
• Granted Patent: US 10,447,062 B2
• Time in Patent Office: 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 wireless charging coil with a high Q factor comprising:

a plurality of wire groups, each comprising;

a plurality of wires spun together in a helical manner to form a self-woven structure of the wire group;

a self-bonding film surrounding the plurality of wires; and

a plurality of insulation layers, each covering a surface of a wire of the plurality of wires;

wherein;

the plurality of wire groups together are wound into a plurality of turns on a same winding surface, all of the plurality of wire groups being wound on the same winding surface; and

each turn is wound by the plurality of wire groups.

2. The wireless charging coil of claim 1, wherein:

first ends of the plurality wire groups are extending from an innermost turn of the plurality of wire groups; and

a thickness of a crossing portion of the plurality wire groups crossing from the innermost turn to an outermost turn is smaller than a thickness of the plurality of wire groups wound on the same winding surface.

3. The wireless charging coil of claim 1, wherein:

each of the plurality wires is an enameled wire.

4. The wireless charging coil of claim 1, wherein:

a number of wire groups in the plurality of wire groups is N;

a width of a cross-section of one turn of the plurality of wire groups to a thickness of the cross-section of one turn of the plurality of wire groups is N;

1; and

N is an integer from 2 to 10.

5. The wireless charging coil of claim 1, wherein:

first ends of the plurality of wire groups are electrically coupled together, and second ends of the plurality of wire groups are electrically coupled together; and

the plurality of wire groups are electrically coupled in parallel on the same winding surface.

6. The wireless charging coil of claim 1, wherein the plurality wire groups are wound into a convex shape.

7. The wireless charging coil of claim 1, wherein the same winding surface is a plane surface, a convex surface or a concave surface.

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

providing a plurality of wire groups, each 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;

the winding machine winding the plurality of wire groups;

fixing second ends of the plurality of wire groups; and

disengaging the passive jig from the active jig.

9. The method of claim 8, further comprising adjusting tensions of the plurality of wire groups separately.

10. The method of claim 9, 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.

11. The method of claim 8, further comprising:

the winding machine 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.

12. The method of claim 8, further comprising bonding the plurality of wire groups before removing the passive jig.

13. The method of claim 12, wherein bonding the plurality of wire groups is performed by hot air bonding, heat resistance bonding and/or solvent bonding the plurality of wires.

14. The method of claim 8, 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 a 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.

15. The method of claim 14, 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.

16. The method of claim 14, 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.

17. The method of claim 14, wherein:

the active jig further comprises a wiring slot disposed on the winding plate of the active jig and extending from a center of the winding plate to an periphery of the winding plate; 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.

18. The method of claim 8, wherein disengaging the passive jig from the active jig comprises making the passive jig and the active jig have different spinning speeds.

19. The method of claim 18, 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.

20. The method of claim 8, wherein the passive jig and the active jig have different spinning speeds when the winding machine winds the plurality of wire groups.

21. The method of claim 8, further comprising coupling the first ends of the plurality of wire groups and coupling the second ends of the plurality of wire groups, wherein the plurality of wire groups are electrically coupled in parallel.

22. The method of claim 8, 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.