Method of making a wireless charging coil

• US 9,490,656 B2
• Filed: 11/25/2014
• Issued: 11/08/2016
• Est. Priority Date: 11/25/2013
• Status: Active Grant

• Current Assignee: AK Stamping Company Inc.
• Original Assignee: AK Stamping Company Inc.
• Inventors: Kurz, Arthur, Duetsch, Bernard, Kurz, Joshua
• Primary Examiner(s): Kim, Paul D
• Application Number:
  US14/553,617
• Publication Number:
  US 20150145635A1
• Time in Patent Office: 714 Days
• Field of Search: 295/921, 296/021, 296/032.3, 296/06, 298/31, 298/32, 298/37, 336/147, 336/222, 336/232
• US Class Current: 1/1
• CPC Class Codes: H01F 27/2847 Sheets; Strips H01F27/2866 takes precedence
• CPC Class Codes: H01F 27/2852 Construction of conductive connections, of leads
• CPC Class Codes: H01F 27/2871 Pancake coils
• CPC Class Codes: H01F 27/36 Electric or magnetic shields or screens movable for varying inductance H01F21/10
• CPC Class Codes: H01F 27/366 made of ferromagnetic material
• 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 5/00 Coils superconducting coils H01F6/06; fixed inductances of the signal type H01F17/00
• 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
• CPC Class Codes: H02J 50/12 of the resonant type
• CPC Class Codes: H02J 7/0042 characterised by the mechanical construction
• CPC Class Codes: H04B 5/263 Multiple coils at either side
• CPC Class Codes: H04B 5/79 for data transfer in combination with power transfer
• CPC Class Codes: Y10T 29/4902 Electromagnet, transformer or inductor

Abstract

A method of making a wireless charging coil. More specifically, a method of making a wireless charging coil is provided comprising stamping a metal sheet to form a first coil having a first spiral trace, applying the first stamped coil to a first laminate, stamping a metal sheet to form a second coil having a second spiral trace, applying the second stamped coil to a second laminate, interpositioning the first stamped coil and the second stamped coil to form a planar coil assembly, the first stamped coil and the second stamped coil positioned between the first and second laminates, heating and pressing the planar coil assembly to displace and set the adhesive of the first and second laminates to surround and bond together the first and second coils.

Claims

1. A method of making a wireless charging coil comprising:

stamping a metal sheet to form a first coil having a first spiral trace, the first spiral trace defining a first space between windings;

applying the first stamped coil to a first laminate via a first adhesive thereof;

stamping a metal sheet to form a second coil having a second spiral trace, the second spiral trace defining a second space between windings;

applying the second stamped coil to a second laminate via a second adhesive thereof;

interpositioning the first stamped coil and the second stamped coil to form a planar coil assembly with the first stamped coil positioned within the second space of the second stamped coil, the second stamped coil positioned within the first space of the first stamped coil, and the first stamped coil and the second stamped coil positioned between the first and second laminates; and

heating and pressing the planar coil assembly to displace and set the first and second adhesives of the first and second laminates to surround and bond together the first and second coils.

2. The method of claim 1, wherein heat applied by a heat press melts the adhesive but does not melt the laminate.

3. The method of claim 2, wherein the pressure applied by the heat press displaces and forces the adhesive between the first trace of the first coil and the second trace of the second coil to insulate the coils.

4. The method of claim 1, wherein stamping the metal sheet forms the first coil with tie bars.

5. The method of claim 4, further comprising stamping the first coil to remove the tie bars.

6. The method of claim 1, wherein the first stamped coil and second stamped coil are connected in series.

7. The method of claim 1, wherein the first stamped coil and second stamped coil are connected in parallel.

8. The method of claim 1, wherein the first stamped coil includes an inside end and an outside end, the inside end disposed on the same side of the first stamped coil as the outside end.

9. The method of claim 8, further comprising a first jumper attached to the outside end of the first coil.

10. The method of claim 9, wherein the second stamped coil includes an inside end and an outside end, and further comprising a second jumper attached to the inside end of the first coil and the outside end of the second coil.

11. The method of claim 10, further comprising a third jumper attached to the inside end of the second coil.