Wireless charging coil

• US 9,859,052 B2
• Filed: 08/27/2014
• Issued: 01/02/2018
• 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): Lian, Mangtin
• Application Number:
  US14/470,381
• Publication Number:
  US 20150145634A1
• Time in Patent Office: 1,224 Days
• Field of Search: 336232, 336147, 336222, 336200, 29606
• 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 41/04 for manufacturing coils coils for transformer or inductances H01F27/28
• CPC Class Codes: H01F 41/074 Winding flat coils
• CPC Class Codes: H04B 5/79 for data transfer in combination with power transfer
• CPC Class Codes: Y10T 29/49073 by assembling coil and core

Abstract

A wireless charging coil is provided herein. The wireless charging coil comprising a first stamped coil having a first spiral trace, the first spiral trace defining a first space between windings, and a second stamped coil having a second spiral trace, the second spiral trace defining a second space between windings, wherein the first stamped coil and second stamped coil are planar to and interconnected with one another, such that the first stamped coil is positioned within the second space of the second stamped coil, and the second stamped coil is positioned within the first space of the first stamped coil.

Claims

1. A wireless charging coil comprising:

a first stamped coil having a first spiral trace with a rectangular cross-section, the first spiral trace defining a first space between windings, the first spiral trace having a width that varies along a length of the first stamped coil; and

a second stamped coil having a second spiral trace with a rectangular cross-section, the second spiral trace defining a second space between windings, the second spiral trace having a width that varies along a length of the second stamped coil,

the first stamped coil and second stamped coil positioned in the same plane and interconnected with one another, the first stamped coil positioned within the second space of the second stamped coil, and the second stamped coil positioned within the first space of the first stamped coil, when assembled the first spiral trace and the second spiral trace have a fill ratio greater than 65%.

2. The bifilar wireless charging coil of claim 1, wherein the first stamped coil and second stamped coil are connected in series.

3. The bifilar wireless charging coil of claim 1, wherein the first stamped coil and second stamped coil are of a generally rectangular shape.

4. The bifilar wireless charging coil 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.

5. The bifilar wireless charging coil of claim 1, wherein the first and second traces have a thickness between 0.003 inches and 0.020 inches.

6. The bifilar wireless charging coil of claim 1, wherein the first and second traces have a width between 0.005 inches and 0.250 inches.

7. The bifilar wireless charging coil of claim 1, wherein the first and second coils each include an inside end and an outside end, the inside end of the first coil disposed on a same side of the wireless charging coil as the outside end of the second coil, and further comprising a jumper electrically connecting the inside end of the first coil with the outside end of the second coil.

8. The bifilar wireless charging coil of claim 1, further comprising a ferrite substrate, the first and second coils applied to the ferrite substrate.

9. The bifilar wireless charging coil of claim 1, wherein the fill ratio is approximately 85%.