FLEXIBLE PLATE ADAPTED TO BE USED IN WINGED COIL STRUCTURE, WINGED COIL STRUCTURE, AND METHOD OF MANUFACTURING WINGED COIL STRUCTURE

• US 20180068777A1
• Filed: 11/13/2017
• Published: 03/08/2018
• Est. Priority Date: 10/08/2015
• Status: Active Application

• 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 10,256,030 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 flexible plate adapted to be used in a winged coil structure for providing a function of magnetic induction and a flexible and bendable feature, wherein the flexible plate is formed of a flexible substrate with electrical insulation and has a middle region and two side regions bordering the middle region;

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

2. 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:

the flexible plate according to claim 1;

at least one upper magnetic induction coil embedded in the flexible plate and having a helical shape close to an upper surface of the 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 and having a middle region and two side regions bordering the middle region;

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;

the dielectric layer provided between the flexible plate and the lower flexible plate, the flexible plate being on an upper surface of the dielectric layer, the lower flexible plate beneath a lower surface of the dielectric layer; and

at least one connection plug formed of an electrically conductive metal material, the at least one connection plug penetrating the dielectric layer and provided between the corresponding upper connection pad and lower connection pad, the at least one connection plug combines the at least one upper connection pad with the at least one lower connection pad, respectively,

wherein the at least one upper magnetic induction coil and the at least one lower magnetic induction coil are separated by the dielectric layer, and the notched line is provided along each adjacency of the lower surface of the flexible plate and the lower flexible plate.

3. The winged coil structure according to claim 2, wherein the middle region of the flexible plate has a first middle through-hole, the middle region of the lower flexible plate has a second middle through-hole, the at least one upper magnetic induction coil and the at least one lower magnetic induction coil are configured around the first middle through-hole of the flexible plate and the second middle through-hole of the lower flexible plate, respectively.

4. The winged coil structure according to claim 2, wherein the dielectric layer has at least one through-hole, the at least one through-hole is aligned to the at least one upper connection pad and the at least one lower connection pad, respectively.

5. The winged coil structure according to claim 2, further comprising at least one gold finger configured at the side regions of the flexible plate and electrically connected with the at least one lower magnetic induction coil.

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:

the flexible plate according to claim 1;

at least one upper magnetic induction coil embedded in the flexible plate and having a helical shape close to an upper surface of the 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 and having a middle region and two side regions bordering the middle region;

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;

the dielectric layer provided between the flexible plate and the lower flexible plate, the flexible plate being on an upper surface of the dielectric layer, the lower flexible plate beneath a lower surface of the dielectric layer;

at least one connection plug formed of an electrically conductive metal material, the at least one connection plug penetrating the dielectric layer and provided between the corresponding upper connection pad and lower connection pad, the at least one connection plug combines the at least one upper connection pad with the at least one lower connection pad, respectively;

a bottom flexible plate formed of a yet flexible substrate with electrical insulation and having a middle region and two side regions bordering the middle region;

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 at least one lower connection pad,

wherein the at least one upper magnetic induction coil and the at least one lower magnetic induction coil are separated by the dielectric layer, and the notched line is provided along each adjacency of the lower surface of the flexible plate and the lower flexible plate.

7. The winged coil structure according to claim 6, wherein the middle region of the flexible plate has a first middle through-hole, the middle region of the lower flexible plate has a second middle through-hole, the middle region of the bottom flexible plate has a third middle through-hole, the at least one upper magnetic induction coil, the at least one lower magnetic induction coil, and the at least one bottom magnetic induction coil are configured around the first middle through-hole of the flexible plate, the second middle through-hole of the lower flexible plate, and the third middle through-hole of the bottom flexible plate, respectively.

8. The winged coil structure according to claim 6, wherein the dielectric layer has at least one through-hole, the at least one through-hole is aligned to the at least one upper connection pad and the at least one lower connection pad, respectively.

9. The winged coil structure according to claim 6, further comprising at least one gold finger configured at the side regions of the flexible plate and electrically connected with the at least one lower magnetic induction coil.

10. 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, and at least one connection plug, the at least one upper magnetic induction coil and the at least one 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 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 of the dielectric layer being the same as a lateral size of the middle region of the upper flexible plate;

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 at least one lower magnetic induction coil and the at least one lower connection pad being electrically connected and embedded in the middle region of the lower flexible plate and close to a 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 at least one connection plug being formed of an electrically conductive metal material configured to penetrate the dielectric layer, and provided between the corresponding upper and lower connection pads such that the at least one connection plug 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.

11. The method according to claim 10, wherein a middle through-hole is provided at the middle region of the upper flexible plate, at least one middle through-hole is provided at a middle region of the dielectric layer, and a middle through-hole is provided at the middle region of the lower flexible plate, the respective middle through-holes of the lower flexible plate, the dielectric layer, and the upper flexible plate are vertically aligned in the multiple layered stack structure, and the at least one connection plug is configured to penetrate the at least one middle through-hole of the dielectric layer.

12. The method according to claim 10, wherein the upper flexible plate is further provided with at least one gold finger, and the at least one gold finger is provided on lower surfaces of the two side regions of the upper flexible plate.

13. 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, and at least one connection plug, the at least one upper magnetic induction coil and the at least one 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 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 of the dielectric layer being the same as a lateral size of the middle region of the upper flexible plate;

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 at least one lower magnetic induction coil and the at least one 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, the bottom flexible plate 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 at least one bottom magnetic induction coil and the at least one 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 at least one connection plug being formed of an electrically conductive metal material, configured to penetrate the dielectric layer, and provided between the corresponding upper and lower connection pads such that the at least one connection plug 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.

14. The method according to claim 13, wherein a middle through-hole is provided at the middle region of the upper flexible plate, at least one middle through-hole is provided at a middle region of the dielectric layer, a middle through-hole is provided at the middle region of the lower flexible plate, and a middle through-hole is provided at the middle region of the bottom flexible plate, the respective middle through-holes of the bottom flexible plate, the lower flexible plate, the dielectric layer, and the upper flexible plate are vertically aligned in the multiple layered stack structure, and the at least one connection plug is configured to penetrate the at least one middle through-hole of the dielectric layer.

15. The method according to claim 13, wherein the upper flexible plate is further provided with at least one gold finger, and the at least one gold finger is provided on lower surfaces of the two side regions of the upper flexible plate.

16. The method according to claim 15, further comprising:

prior to the process of thermal pressing, supporting a bottom of the bottom flexible plate by an auxiliary stuff, wherein the auxiliary stuff is larger than or equal to the upper flexible plate and has two projecting parts at two ends aligned to the at least one gold finger, so that the two side regions of the upper flexible plate and the dielectric layer are supported by the auxiliary stuff during the process of thermal pressing;

removing the auxiliary stuff after the process of thermal pressing; and

covering a covering layer on the upper surface of the upper flexible plate, the lower surface of the lower flexible plate, and a surrounding area of the at least one gold finger, wherein the covering layer is formed of an electrical insulation material with transparency or opaqueness.