3D SHAPED INDUCTIVE CHARGING COIL AND METHOD OF MAKING THE SAME

• US 20170054318A1
• Filed: 03/28/2016
• Published: 02/23/2017
• Est. Priority Date: 08/21/2015
• Status: Active Grant

• Current Assignee: Apple Inc.
• Original Assignee: Apple Inc.
• Inventors: Matsuyuki, Naoto, Graham, Christopher S., Brzezinski, Makiko K.
• Granted Patent: US 10,211,663 B2
• Time in Patent Office: Days
• US Class Current: 1/1
• CPC Class Codes: H01F 2027/2809 on stacked layers
• CPC Class Codes: H01F 27/2871 Pancake coils
• CPC Class Codes: H01F 27/327 Encapsulating or impregnating encapsulating coil and core H01F27/022
• 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 41/127 Encapsulating or impregnating encapsulating coil and core H01F41/005
• CPC Class Codes: H01L 23/5226 Via connections in a multilevel interconnection structure
• CPC Class Codes: H01L 23/5227 Inductive arrangements or effects of, or between, wiring layers other inductive arrangements H01L23/645
• 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 three-dimensional inductive charging coil assembly and a method of making the same. The method can include patterning a first conductive layer affixed to a first surface of an insulating layer to form a coil configured to transmit or receive power, patterning a second conductive layer affixed to a second surface of the insulating layer opposite the first surface to form a conductive trace element, and electrically coupling the coil and the conductive trace element. The coil, insulating layer, and conductive trace element can be molded (e.g., simultaneously) into a three dimensional shape. In some embodiment, the molding can include a thermoforming process such as compression molding, vacuum forming, or the like.

Claims

1. A method of making a three-dimensional inductive coil assembly for wireless charging comprising:

patterning a first conductive layer affixed to a first surface of an insulating layer to form a coil configured to transmit or receive power;

patterning a second conductive layer affixed to a second surface of the insulating layer opposite the first surface to form a conductive trace element;

electrically coupling the coil and the conductive trace element; and

molding the coil, the insulating layer, and the conductive trace element into a three-dimensional shape.

2. The method of claim 1 wherein the coil, the insulating layer, and the conductive trace element are molded simultaneously.

3. The method of claim 1 wherein molding comprises a vacuum forming process.

4. The method of claim 1 wherein molding comprises a compression molding process.

5. The method of claim 1 wherein patterning the first conductive layer comprises etching the first conductive layer to form the coil.

6. The method of claim 1 wherein patterning the second conductive layer comprises etching the second conductive layer to form the conductive trace element.

7. The method of claim 1 wherein electrically coupling the coil and the conductive trace element comprises forming a via through the insulating layer.

8. The method of claim 1, further comprising:

laminating the coil and an exposed region of the first surface of the insulating layer prior to molding.

9. The method of claim 1, further comprising:

depositing a ferrite layer onto the conductive trace element and an exposed region of the second surface of the insulating layer prior to molding.

10. The method of claim 1 wherein the first conductive layer and the second conductive layer independently comprise a metal.

11. The method of claim 1 wherein the insulating layer comprises a polymer.

12. The method of claim 1 wherein the first conductive layer is adhesively coupled to the first surface of the insulating layer, and wherein the second conductive layer is adhesively coupled to the second surface of the insulating layer.

13. An inductive coil assembly for wireless charging comprising:

an insulating layer comprising a first surface and a second surface opposite the first surface;

a first conductive layer affixed to the first surface of the insulating layer and patterned to form a coil configured to transmit or receive power;

a second conductive layer affixed to the second surface of the insulating layer and patterned to form a conductive trace element, wherein the coil and the conductive trace element are electrically coupled.

14. The coil assembly of claim 13 wherein the first conductive layer, the insulating layer, and the second conductive layer are characterized by a three-dimensional shape.

15. The coil assembly of claim 13 wherein the coil and the conductive trace element are electrically coupled by a via formed through the insulating layer.

16. The coil assembly of claim 14 further comprising a laminate layer disposed on the first conductive layer, wherein the laminate layer is characterized by the three-dimensional shape.

17. An inductive charging component comprising:

a charging surface; and

an inductive coil assembly adjacent to the charging surface, wherein the inductive coil assembly comprises;

a polymer layer comprising a first surface and a second surface opposite the first surface;

a first metal layer adhesively coupled to the first surface of the polymer layer and patterned to form a coil configured to transmit or receive power;

a second metal layer adhesively coupled to the second surface of the insulating layer and patterned to form a conductive trace element; and

a via formed through the polymer layer that electrically couples the coil and the conductive trace element.

18. The inductive charger of claim 17 wherein the charging surface is non-planar, and wherein the inductive coil assembly is characterized by a three-dimensional shape such that it conforms to a contour of the nonplanar charging surface.

19. The inductive charger of claim 17 wherein the inductive coil assembly further comprises:

a laminate layer disposed on the first metal layer.

20. The inductive charger of claim 17 wherein the inductive coil assembly further comprises:

a ferrite layer disposed on a second metal layer.