CN204361741U - Thin film coil element and related charging device - Google Patents
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- CN204361741U CN204361741U CN201520038325.9U CN201520038325U CN204361741U CN 204361741 U CN204361741 U CN 204361741U CN 201520038325 U CN201520038325 U CN 201520038325U CN 204361741 U CN204361741 U CN 204361741U
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Abstract
一种薄膜线圈元件以及相关充电装置,其中薄膜线圈元件结构上以一粘接层形成元件的中心结构,制作过程中以导电薄膜材料为基材,而粘接层形成于此基材上,经过图案化制程形成在粘接层的两个表面上的薄膜线圈结构,经形成贯穿粘接层的导体连接部,导体连接结构即电连接粘接层两个表面上的薄膜线圈结构,于是形成薄膜线圈元件,之后可组合多个薄膜线圈元件制作一应用线圈电磁感应技术的充电装置。
A thin film coil element and a related charging device, wherein the thin film coil element structure uses an adhesive layer to form the central structure of the element. During the manufacturing process, a conductive film material is used as a substrate, and the adhesive layer is formed on this substrate. A thin film coil structure is formed on two surfaces of the adhesive layer through a patterning process. A conductor connection portion is formed that passes through the adhesive layer. The conductor connection structure electrically connects the thin film coil structure on the two surfaces of the adhesive layer, thereby forming a thin film coil element. Thereafter, multiple thin film coil elements can be combined to produce a charging device that uses coil electromagnetic induction technology.
Description
技术领域technical field
本实用新型为一种线圈元件以及相关的充电装置,特别是指以一薄膜形导体线圈结构形成的薄膜线圈元件,以及多个薄膜线圈元件组合形成的充电装置。The utility model relates to a coil element and a related charging device, in particular to a thin film coil element formed with a thin film conductor coil structure, and a charging device formed by combining a plurality of thin film coil elements.
背景技术Background technique
无线充电,又称作感应充电或非接触式感应充电,是利用近场感应,也就是电感耦合,由供电设备将能量传输至用电装置。一般技术为在充电器中设有一磁芯,再于外部绕铜线圈,通电后可产生在某一个方向的电磁场,若施以交流电可产生交流电磁场,若在用电装置内有另一线圈接收交流电磁场,可转化为电能,而供电给用电装置,或对其内的充电电池进行充电。由于充电器与用电装置之间以电感耦合传送能量,没有电线连接的必要。Wireless charging, also known as inductive charging or non-contact inductive charging, uses near-field induction, that is, inductive coupling, to transmit energy from power supply equipment to electrical devices. The general technology is to set a magnetic core in the charger, and then wind a copper coil outside. After electrification, an electromagnetic field in a certain direction can be generated. If an alternating current is applied, an alternating electromagnetic field can be generated. If there is another coil in the electrical device to receive The AC electromagnetic field can be converted into electrical energy to supply power to the electrical device or to charge the rechargeable battery inside it. Since the energy is transmitted by inductive coupling between the charger and the electric device, there is no need for wire connection.
传统的线圈设计如图1A与图1B所示。图1A显示为一般无线充电模组的线圈,匝数为三圈,一端通电后能产生一感应电磁场强度。为了增加感应电磁场强度,可如图1B所示,可增加平面线圈的绕线匝数至六圈,理论上可以增加感应电磁场强度至两倍。但是这样会使线长增加两倍以上,而影响到线圈整体的电阻值,降低无线充电的效率。The traditional coil design is shown in Fig. 1A and Fig. 1B. FIG. 1A shows the coil of a general wireless charging module, with three turns, and an induced electromagnetic field strength can be generated after one end is energized. In order to increase the intensity of the induced electromagnetic field, as shown in FIG. 1B , the number of winding turns of the planar coil can be increased to six turns, and theoretically the intensity of the induced electromagnetic field can be doubled. However, this will increase the wire length by more than two times, which will affect the overall resistance value of the coil and reduce the efficiency of wireless charging.
同时,无线充电仍有部分缺点待克服,如效率略低,一般充电器内也有变压器,但无线充电以第一线圈和第二线圈的组成,由于在结构上有限制,能量传送效率会略低一般充电器,再加上电源先由外部电路作降压、整流及稳压后再到无线充电模组,转换效率也会受限于外部电路的设计;以无线充电方式会因匝数增加导致线阻提升而发热严重,其与传统充电器有相同的问题,即便是正在充电时,会产生发热的现象。At the same time, wireless charging still has some shortcomings to be overcome, such as slightly lower efficiency. Generally, there is a transformer in the charger, but wireless charging is composed of the first coil and the second coil. Due to structural limitations, the energy transmission efficiency will be slightly lower. In general chargers, plus the power supply is first stepped down, rectified and stabilized by the external circuit before being sent to the wireless charging module, the conversion efficiency will also be limited by the design of the external circuit; The wire resistance is increased and the heat is serious. It has the same problem as the traditional charger. Even when charging, it will generate heat.
实用新型内容Utility model content
本说明书公开一种薄膜线圈元件以及相关充电装置,其中薄膜线圈元件结构上以一粘接层形成元件的中心结构,制作过程中以导电薄膜材料为基材,而粘接层形成于此基材上,经过图案化制程形成在粘接层的两个表面上的薄膜线圈结构,经形成贯穿粘接层的导体连接部,导体连接结构即电连接粘接层两个表面上的薄膜线圈结构,于是形成薄膜线圈元件,之后可组合多个薄膜线圈元件制作一应用线圈电磁感应技术的充电装置。This specification discloses a thin film coil element and related charging device, wherein the structure of the thin film coil element uses an adhesive layer to form the central structure of the element, and a conductive thin film material is used as the base material in the manufacturing process, and the adhesive layer is formed on the base material Above, the thin film coil structure formed on the two surfaces of the adhesive layer through the patterning process, and the conductor connection part penetrating through the adhesive layer is formed, and the conductor connection structure is the thin film coil structure electrically connected on the two surfaces of the adhesive layer, Thus, the thin film coil element is formed, and then a plurality of thin film coil elements can be combined to manufacture a charging device using coil electromagnetic induction technology.
根据实施例之一,薄膜线圈元件包括一形成中心结构的粘接层,其中材料可混有磁性材料,元件包括一第一薄膜线圈,形成于粘接层的第一表面上,由螺旋结构的第一薄膜绕线所组成,第一薄膜绕线的外侧具有对外连线的第一连接端口,内侧则具有第一绕线终点;另有一第二薄膜线圈,形成于粘接层的第二表面上,由螺旋结构的第二薄膜绕线所组成,第二薄膜绕线的外侧具有对外连线的第二连接端口,内侧具有第二绕线终点。According to one embodiment, the thin-film coil element includes an adhesive layer forming a central structure, wherein the material may be mixed with magnetic material, and the element includes a first thin-film coil formed on a first surface of the adhesive layer, formed by a helical structure. Composed of the first film winding, the outer side of the first film winding has the first connection port for the external connection, and the inner side has the first winding end point; there is also a second film coil formed on the second surface of the adhesive layer On the top, it is composed of the second film winding in a helical structure, the outside of the second film winding has a second connection port for external connection, and the inside has a second winding terminal.
第一薄膜线圈与第二薄膜线圈之间可以一导体连接部相互电连接,导体连接部贯穿粘接层,连接了第一绕线终点与第二绕线终点。The first thin-film coil and the second thin-film coil can be electrically connected to each other by a conductor connecting portion, which penetrates through the adhesive layer and connects the first winding end point and the second winding end point.
在此结构中,经粘接层两侧的薄膜线圈的第一连接端口与第二连接端口之间的电流可于薄膜线圈元件中形成一感应电磁场,而混有磁性材料的粘接层可增加薄膜绕线的感应电流与感应电动势。In this structure, the current between the first connection port and the second connection port of the thin film coil on both sides of the adhesive layer can form an induced electromagnetic field in the thin film coil element, and the adhesive layer mixed with magnetic material can increase Induced current and induced electromotive force in thin film winding.
在一实施例中,形成于基板两侧的螺旋结构的第一薄膜绕线与第二薄膜绕线中心部位各别也可形成有薄膜磁芯。In an embodiment, the central parts of the first thin film winding and the second thin film winding of the helical structure formed on both sides of the substrate may also be respectively formed with a thin film magnetic core.
根据说明书所载实施例,组合以上一或多个薄膜线圈元件形成一充电装置,可用以对具有一对应线圈的电子装置充电,充电装置包括一或多个薄膜线圈元件,其中各薄膜线圈元件主要元件有一混有磁性材料的粘接层,以及形成于粘接层两侧的第一薄膜线圈与第二薄膜线圈,再以一导体连接部贯穿粘接层,以电连接第一薄膜线圈与第二薄膜线圈。充电装置更包括一电源管理单元,能够管理与控制由充电装置内一或多个薄膜线圈元件产生的感应电力。According to the embodiment contained in the description, the above one or more thin film coil elements are combined to form a charging device, which can be used to charge an electronic device with a corresponding coil. The charging device includes one or more thin film coil elements, wherein each thin film coil element is mainly The element has an adhesive layer mixed with magnetic material, and a first thin film coil and a second thin film coil formed on both sides of the adhesive layer, and a conductor connecting portion penetrates the adhesive layer to electrically connect the first thin film coil and the second thin film coil. Two thin-film coils. The charging device further includes a power management unit capable of managing and controlling the induced power generated by one or more thin film coil elements in the charging device.
为了能更进一步了解本实用新型为达成既定目的所采取的技术、方法及效果,请参阅以下有关本实用新型的详细说明、附图,相信本实用新型的目的、特征与特点,当可由此得以深入且具体的了解,然而所附附图与附件仅提供参考与说明用,并非用来对本实用新型加以限制者。In order to further understand the technology, method and effect that the utility model adopts to achieve the established purpose, please refer to the following detailed description and accompanying drawings of the utility model, and believe that the purpose, characteristics and characteristics of the utility model can be obtained from this In-depth and specific understanding, however, the accompanying drawings and appendices are only for reference and description, and are not used to limit the utility model.
附图说明Description of drawings
图1A与图1B示意显示一般铜线圈的形式;1A and 1B schematically show the form of a general copper coil;
图2A、2B显示本实用新型元件中薄膜线圈的实施例示意图;Fig. 2A, 2B show the schematic diagram of the embodiment of thin film coil in the element of the present invention;
图3显示本实用新型薄膜线圈元件的实施例示意图;Fig. 3 shows the schematic diagram of the embodiment of the thin film coil element of the present invention;
图4A至图4F显示制作本实用新型的薄膜线圈元件的实施例流程;Fig. 4A to Fig. 4F show the embodiment process of making the thin film coil element of the present utility model;
图5显示本实用新型具有磁芯结构的薄膜线圈的实施例示意图;Fig. 5 shows the schematic diagram of the embodiment of the thin film coil with magnetic core structure of the present invention;
图6显示本实用新型薄膜线圈元件实施例的剖面示意图;Figure 6 shows a schematic cross-sectional view of an embodiment of the thin film coil element of the present invention;
图7为本实用新型充电装置的实施例示意图。Fig. 7 is a schematic diagram of an embodiment of the charging device of the present invention.
【符号说明】【Symbol Description】
第一薄膜线圈21 第二薄膜线圈22First film coil 21 Second film coil 22
第一薄膜绕线201 第二薄膜绕线202First film winding 201 Second film winding 202
第一连接端口203 第二连接端口204The first connection port 203 The second connection port 204
第一绕线终点207 第二绕线终点208The first winding end point 207 The second winding end point 208
导体连接部301 粘接层30Conductor connection part 301 Adhesive layer 30
第一导电薄膜基材401 第一薄膜线圈401’The first conductive film substrate 401 The first film coil 401'
粘接层材料403 粘接层403’Adhesive layer material 403 Adhesive layer 403'
第二导电薄膜材料402 第二薄膜线圈402’The second conductive film material 402 The second film coil 402'
导体连接部405 第一连接端口407Conductor connection part 405 First connection port 407
第二连接端口408 第一薄膜磁芯409The second connection port 408 The first thin-film magnetic core 409
第二薄膜磁芯410 保护层400The second thin film magnetic core 410 protective layer 400
薄膜线圈51, 51’薄膜绕线501Thin film coil 51, 51' film winding 501
连接端口503,503’ 薄膜磁芯505,505’Connection ports 503, 503' Thin film cores 505, 505'
绕线终点507,507’Winding end point 507,507'
粘接层60 导体连接部601Adhesive layer 60 Conductor connecting part 601
基板70 薄膜线圈元件701Substrate 70 Thin film coil element 701
电源管理单元703 电源705Power Management Unit 703 Power Supply 705
电子装置72 装置端薄膜线圈元件721Electronic device 72 Thin film coil element at the device end 721
具体实施方式Detailed ways
本实用新型提出一种薄膜线圈元件,是一种透过薄膜技术制作薄型而且可导电的薄膜装置,本实用新型也涉及利用此薄膜线圈组合而成的充电装置,特别是一种具有特定线宽而经通电能产生感应电磁场的薄膜线圈,可以应用于无线充电的高增益薄膜线圈设计,经组合多个薄膜线圈形成充电装置。The utility model proposes a thin-film coil element, which is a thin and conductive thin-film device made through thin-film technology. The utility model also relates to a charging device combined with the thin-film coil, especially a charging device with a specific line width. The thin-film coil that can generate an induced electromagnetic field by being energized can be applied to the high-gain thin-film coil design of wireless charging, and a charging device is formed by combining multiple thin-film coils.
值得一提的是,本实用新型所提出的薄膜线圈元件采用元件中的一粘接层成为薄膜线圈元件的中心结构,也就是减少了一般会采用塑胶或特定材料的基材结构,制作过程中可以一导电薄膜材料为基材,比如是一金属箔,接着涂布一粘接材料在此基材上,并再于粘接材料的另一表面结合另一导电薄膜材料,之后经过图案化制程形成在粘接层的两个表面上的薄膜线圈结构,再以贯穿粘接层的导体连接部连接两个薄膜线圈结构后形成薄膜线圈元件。It is worth mentioning that the thin-film coil element proposed by the utility model adopts an adhesive layer in the element to become the central structure of the thin-film coil element, that is, it reduces the base material structure that usually uses plastic or specific materials. A conductive film material can be used as a substrate, such as a metal foil, and then an adhesive material is coated on the substrate, and another conductive film material is bonded to the other surface of the adhesive material, and then patterned The thin film coil structures are formed on the two surfaces of the adhesive layer, and then the two thin film coil structures are connected by a conductor connecting portion penetrating the adhesive layer to form a thin film coil element.
说明书所公开的薄膜线圈元件的实施例采用薄膜设计的效果之一即便是增加匝数也不会明显提升线圈整体的电阻值,可以有效提升充电效率,比如将充电效率从70%提升至80%以上,且不易有发热的问题。此外,薄膜线圈的实施例之一可将线圈薄型化,并可立体化,可助于整个无线充电装置的可挠性(flexibility)与薄型化(miniaturization),比如薄度可小于0.5mm。One of the effects of using thin-film design in the embodiment of the thin-film coil element disclosed in the specification is that even if the number of turns is increased, the overall resistance of the coil will not be significantly increased, and the charging efficiency can be effectively improved, such as increasing the charging efficiency from 70% to 80%. above, and it is not easy to have the problem of heating. In addition, one embodiment of the thin film coil can make the coil thinner and three-dimensional, which can help the flexibility and miniaturization of the whole wireless charging device, for example, the thinness can be less than 0.5 mm.
图2A显示本实用新型元件中的薄膜线圈的实施例示意图之一,此例的薄膜线圈为具有一螺旋方向的第一薄膜线圈21,由螺旋结构的第一薄膜绕线201所组成,形成多匝数的薄膜线圈。此薄膜绕线较佳为由导体材料制成的薄膜,螺旋结构中相邻结构具有一间距,使得电气信号不致互相耦合或影响。此第一薄膜绕线201的外侧具有对外(外部电路)连线的一连接端口,如图示的第一连接端口203,而内侧则具有一绕线终点,如图示的第一绕线终点207。Fig. 2A shows one of the embodiment schematic diagrams of the thin film coil in the element of the present invention, the thin film coil of this example is the first thin film coil 21 with a helical direction, is made up of the first thin film winding wire 201 of spiral structure, forms multiple Thin film coil with turns. The thin film winding is preferably a thin film made of conductive material, and the adjacent structures in the helical structure have a distance, so that the electrical signals will not be coupled or affected by each other. The outside of the first film winding 201 has a connection port for external (external circuit) connection, such as the first connection port 203 shown in the figure, while the inside has a winding end point, such as the first winding end point shown in the figure 207.
相对地,图2B接着示意表示有一个螺旋方式相反的第二薄膜线圈22,由螺旋结构的第二薄膜绕线202所组成,同样在相邻的结构有一间距,此间距与上述第一薄膜线圈21的结构间距实质上可一致,但也可不一致。同样地,第二薄膜绕线202外侧有对外连线的第二连接端口204,内侧终端则有第二绕线终点208。In contrast, FIG. 2B then schematically shows that there is a second thin film coil 22 with the opposite helical mode, which is composed of a second thin film winding 202 in a helical structure, and there is also a distance between adjacent structures, which is the same as that of the first thin film coil described above. The structural pitches of 21 may be substantially uniform, but may not be uniform. Similarly, the second film winding 202 has a second connection port 204 for external connection on the outside, and a second winding end point 208 on the inside.
于上述薄膜线圈(第一薄膜线圈21、第二薄膜线圈22)中,经提供电力,电流经各线圈的对外连接端口(第一连接端口203、第二连接端口204)到绕线终点(第一绕线终点207、第二绕线终点208),可以形成一感应电磁场。In the above-mentioned thin film coils (the first thin film coil 21, the second thin film coil 22), through the supply of power, the current passes through the external connection ports (the first connection port 203, the second connection port 204) of each coil to the winding end point (the second connection port 204). The first winding end point 207 and the second winding end point 208 ) can form an induced electromagnetic field.
设计上,第一薄膜线圈21与第二薄膜线圈22在实际需求下,螺旋结构中的相邻绕线的间距可以相同或不同,也可以包括相同匝数或是不同的匝数,甚至线圈面积也可不同。In terms of design, under the actual needs of the first thin film coil 21 and the second thin film coil 22, the spacing between adjacent windings in the helical structure can be the same or different, and can also include the same number of turns or different numbers of turns, and even the coil area It can also be different.
材料上,形成第一薄膜线圈21、第二薄膜线圈22的薄膜绕线(201、202)较佳可为一可挠式的铜薄膜,而实际实现时,材料并不限于铜。薄膜线圈的螺旋结构为一矩形螺旋结构或一圆形螺旋结构,而实际实现时,不受限于上述形状。In terms of material, the thin-film windings ( 201 , 202 ) forming the first thin-film coil 21 and the second thin-film coil 22 are preferably a flexible copper thin film, but in actual implementation, the material is not limited to copper. The helical structure of the thin film coil is a rectangular helical structure or a circular helical structure, and is not limited to the above shapes in actual implementation.
根据实施例,若结合了上述的薄膜线圈,比如在一结构平面的两个表面上分别结合上述第一、第二薄膜线圈,可形成一薄膜线圈元件,如图3所示的本实用新型薄膜线圈元件实施例示意图。According to an embodiment, if the above-mentioned thin film coil is combined, for example, the above-mentioned first and second thin film coils are respectively combined on two surfaces of a structural plane, a thin film coil element can be formed, as shown in FIG. Schematic diagram of an embodiment of a coil element.
图中显示为本实用新型薄膜线圈元件实施例的剖面图,实际正向图形可以如前述的矩形螺旋结构或圆形螺旋结构。剖面图显示主要结构为在一个结构平面的两侧分别形成如前述的薄膜线圈(21、22)。The figure shows a cross-sectional view of an embodiment of the thin film coil element of the present invention, and the actual forward pattern can be as the aforementioned rectangular spiral structure or circular spiral structure. The sectional view shows that the main structure is that the aforementioned thin film coils (21, 22) are respectively formed on both sides of a structural plane.
此例显示中心结构为一粘接层30,实施例之一为混有磁性材料的粘接材料固化所形成。可以形成与薄膜线圈一致的螺旋结构,粘接层30两侧表面分别结合了第一薄膜线圈21(接面定为粘接层30的第一表面)与第二薄膜线圈22(接面定为粘接层30的第二表面),而下方呈现出分别在两个薄膜线圈(21、22)的薄膜绕线的一端的第一连接端口203与第二连接端口204,在第一薄膜线圈21与第二薄膜线圈22之间贯穿粘接层30而以一电连接手段电连接,比如是形成贯穿了粘接层30的一种导体连接部301,电连接两个薄膜线圈(21、22)内部的绕线终点,如图2A、2B所示的第一绕线终点207与第二绕线终点208。如此,等于薄膜线圈元件中的两组薄膜线圈进行串联,得以提升感应电动势与感应电流量,因此可以在相同面积下有两倍的感应电磁场,或是在一定感应电磁场的需求下,仅需一半的面积即可达成。This example shows that the central structure is an adhesive layer 30 , which is formed by curing an adhesive material mixed with magnetic materials in one embodiment. A spiral structure consistent with the film coil can be formed, and the surfaces on both sides of the adhesive layer 30 are respectively combined with the first film coil 21 (the joint surface is defined as the first surface of the adhesive layer 30) and the second film coil 22 (the joint surface is defined as the first surface of the adhesive layer 30 ). The second surface of the adhesive layer 30), and the first connection port 203 and the second connection port 204 at one end of the film windings of the two film coils (21, 22) appear below, respectively, in the first film coil 21 and the second thin film coil 22 through the adhesive layer 30 to be electrically connected by an electrical connection means, such as forming a conductor connection portion 301 through the adhesive layer 30, electrically connecting the two thin film coils (21, 22) The internal winding end points are the first winding end point 207 and the second winding end point 208 shown in FIGS. 2A and 2B . In this way, it is equivalent to connecting two sets of thin film coils in the thin film coil element in series, which can increase the amount of induced electromotive force and induced current, so it can have twice the induced electromagnetic field in the same area, or only half of the required induced electromagnetic field. area can be achieved.
粘接层30的功能除了粘接着第一薄膜线圈21与第二薄膜线圈22,也为两侧薄膜线圈之间的隔绝层,亦可实现薄膜线圈正反面充电,同时也担负整个元件整体结构的基材。两侧线圈上的薄膜绕线形成的螺旋结构应为相同,经第一连接端口203与第二连接端口204之间的电流可形成一致方向的感应电磁场,且螺旋结构中的相邻线圈结构间的间距也可实质相同,但亦不排除依照实际需求有不同的间距。The function of the adhesive layer 30 is not only to bond the first thin film coil 21 and the second thin film coil 22, but also to be an insulating layer between the thin film coils on both sides. base material. The helical structures formed by the thin film windings on the coils on both sides should be the same, and the electric current between the first connection port 203 and the second connection port 204 can form an induced electromagnetic field in the same direction, and the adjacent coil structures in the helical structure The intervals can also be substantially the same, but it does not rule out having different intervals according to actual needs.
形成如前述图3示意显示的薄膜线圈元件的制程可参考图4A至图4F所示的流程。The process of forming the thin film coil element as schematically shown in FIG. 3 may refer to the flow shown in FIG. 4A to FIG. 4F .
在此制作本实用新型的薄膜线圈元件的实施例流程中,开始如图4A,先备置一第一导电薄膜基材401,此为一种导电材料形成的制程中的基板,比如本实施例为一种铜箔基板,其他不排除可为纯铜膜、银导电胶、铜导电胶等。In the process of making the embodiment of the thin film coil element of the present invention, as shown in Figure 4A, a first conductive thin film substrate 401 is prepared first, which is a substrate in the process of forming a conductive material, such as this embodiment It is a kind of copper foil substrate, and others can be pure copper film, silver conductive adhesive, copper conductive adhesive, etc.
在此第一导电薄膜基材401的一个表面上,如图4B所示,先行涂布一粘接层材料403,特别是一种混有具有磁性材料的材料所形成,使得之后形成的粘接层(403’)可以增强元件的电磁感应能力与磁场稳定性。粘接层材料403材料实施例中,其中具有有机材料,而主剂可为环氧树脂、丙烯酸树脂、聚氨酯树脂、压克力树脂、羧基丁腈橡胶、丁腈橡胶等;亦可混有硬化剂,如脂肪族、环状脂肪族、胺类、芳香族硬化剂、光硬化剂等;可混有如锰锌铁氧、镍锌铁氧磁体等的无机材料。粘接层材料403的实际应用也不限于所列举的材料。On one surface of the first conductive film substrate 401, as shown in FIG. 4B, an adhesive layer material 403 is coated in advance, especially a material mixed with a magnetic material to form, so that the bonding formed later The layer (403') can enhance the electromagnetic induction capability and magnetic field stability of the element. In the material embodiment of the bonding layer material 403, there is an organic material, and the main agent can be epoxy resin, acrylic resin, polyurethane resin, acrylic resin, carboxylated nitrile rubber, nitrile rubber, etc.; Agents, such as aliphatic, cycloaliphatic, amines, aromatic hardeners, light hardeners, etc.; can be mixed with inorganic materials such as manganese zinc ferrite, nickel zinc ferrite magnets, etc. The practical application of the adhesive layer material 403 is not limited to the enumerated materials.
当于第一导电薄膜基材401上形成有粘接层材料403之后,如图4C所示,可以在粘接层材料403上另一侧结合另一导电材料,比如上述第一导电薄膜基材401的材料组合(比如纯铜膜、银导电胶、铜导电胶等),以形成第二导电薄膜材料402。After the adhesive layer material 403 is formed on the first conductive film substrate 401, as shown in FIG. 401 (such as pure copper film, silver conductive glue, copper conductive glue, etc.) to form the second conductive film material 402 .
于是,如图4C的初步结构,粘接层材料403成为整个元件的中心结构,也就是排除了一般制程所需的基板结构,因此本实用新型制作无基板的薄膜线圈元件可以达到缩短制程、降低成本、元件薄型微小化的效果。Thus, as shown in the preliminary structure of Figure 4C, the adhesive layer material 403 becomes the central structure of the entire element, that is, the substrate structure required by the general manufacturing process is eliminated. The effect of cost, component thinning and miniaturization.
之后,如图4D所示,经过图案化制程后(patterning),使得粘接层403’上下的第一导电薄膜基材401与第二导电薄膜材料402形成如图所示的薄膜线圈元件的实施方式之一。根据实施例之一,图案化如黄光制程,曝光微影蚀刻(photolithography etching)以上二个导电薄膜材料(401,402),以形成所需的薄膜线圈结构。After that, as shown in FIG. 4D, after patterning, the first conductive film substrate 401 and the second conductive film material 402 above and below the adhesive layer 403' form the implementation of the thin film coil element as shown in the figure. one of the ways. According to one embodiment, the above two conductive thin film materials ( 401 , 402 ) are patterned, such as photolithography, to form the desired thin film coil structure.
本实用新型不排除使用粘接层材料403当作制程中的基板,用网印、粘结或是其他制程方式在将第一导电薄膜材料401与第二导电薄膜材料402设置在粘接层材料403两个表面上之后做图案化处理;甚至直接将已图案化的第一导电薄膜材料401与第二导电薄膜材料402设置在粘接层材料403两个表面上。The utility model does not exclude the use of the adhesive layer material 403 as the substrate in the process, and the first conductive film material 401 and the second conductive film material 402 are arranged on the adhesive layer material by screen printing, bonding or other process methods. 403 on both surfaces and then patterning; even the patterned first conductive film material 401 and the second conductive film material 402 are directly disposed on the two surfaces of the adhesive layer material 403 .
于是,透过图案化制程,同时形成如具有如图4D所示的螺旋结构的第一薄膜线圈401’以及第二薄膜线圈402’,必要时,粘接层材料403可以透过一固化程序完成固化(如光固化、热固化或光热附合型固化),形成粘接层403’,包括粘接层403’中的磁性材料具有混于粘接层材料中的铁磁颗粒,可经固化形成粘接层403’,以强固整体无基板的结构。Thus, through the patterning process, the first thin film coil 401' and the second thin film coil 402' having a spiral structure as shown in FIG. 4D are simultaneously formed. If necessary, the adhesive layer material 403 can be completed through a curing process. Curing (such as light curing, thermal curing or photothermal bonding type curing) to form an adhesive layer 403', including the magnetic material in the adhesive layer 403' having ferromagnetic particles mixed in the adhesive layer material, which can be cured An adhesive layer 403' is formed to strengthen the overall substrate-less structure.
其中,第一薄膜线圈401’形成于粘接层403’的一表面上(可定为第一表面),如图2A、2B所示的实施方式,由一螺旋结构的第一薄膜绕线所组成,第一薄膜绕线的螺旋结构中相邻结构具有一间距,并且根据用途在第一薄膜绕线的外侧形成对外连线的第一连接端口,内侧则是具有第一绕线终点。第二薄膜线圈402’为形成于该粘接层的另一表面(可定为第二表面),同样由如第一薄膜线圈401’相同形式的螺旋结构第二薄膜绕线所组成,其中第二薄膜绕线的螺旋结构中相邻结构也具有一间距,而此间距具有与第一薄膜线圈401’中薄膜绕线的间距相同或不同的距离,同样地,第二薄膜绕线的外侧具有对外连线的第二连接端口,内侧具有第二绕线终点。Wherein, the first thin film coil 401' is formed on one surface of the adhesive layer 403' (which can be designated as the first surface). Composition, the adjacent structures in the helical structure of the first film winding have a distance, and according to the application, the first connection port for the external connection is formed on the outside of the first film winding, and the first winding end point is formed on the inside. The second thin film coil 402' is formed on the other surface of the adhesive layer (can be designated as the second surface), and is also composed of a second thin film coil with a helical structure in the same form as the first thin film coil 401', wherein the second thin film coil Adjacent structures in the helical structure of the two thin-film windings also have a pitch, and this pitch has the same or different distance from the pitch of the thin-film windings in the first thin-film coil 401'. Similarly, the outer side of the second thin-film winding has The second connection port for the external connection has a second winding end point inside.
图4E接着以剖面图表示第一薄膜线圈401’与第二薄膜线圈402’之间可以形成一个贯穿粘接层403’的电连接结构,如图所示,形成一导体连接部405,可以电连接第一薄膜线圈401’与第二薄膜线圈402’分别在其绕线终点形成的电接点。而在第一薄膜线圈401’与第二薄膜线圈402’分别的对外端点,可以形成如图显示的第一连接端口407与第二连接端口408。FIG. 4E then shows in a cross-sectional view that an electrical connection structure through the adhesive layer 403' can be formed between the first thin film coil 401' and the second thin film coil 402'. As shown in the figure, a conductor connection part 405 is formed, which can be electrically connected. Connect the electrical contacts formed at the winding end points of the first thin film coil 401 ′ and the second thin film coil 402 ′ respectively. On the external terminals of the first thin film coil 401' and the second thin film coil 402' respectively, a first connection port 407 and a second connection port 408 as shown in the figure can be formed.
导体连接部405形成的方式,根据实施例,可以先在粘接层403’上贯孔,以填入导电材料,导体连接部405可以电镀纯铜膜、无电镀纯铜膜、银导电胶或铜导电胶所形成。The way of forming the conductor connection part 405, according to the embodiment, can first penetrate the hole on the adhesive layer 403' to fill in the conductive material. The conductor connection part 405 can be electroplated pure copper film, electroless plated pure copper film, silver conductive glue or Copper conductive glue is formed.
更进一步地,根据再一实施例中,上述由第一薄膜线圈401’、粘接层403’以及第二薄膜线圈402’形成的主体结构上,可以在螺旋结构的两侧形成,也就是靠近第一薄膜线圈401’的第一薄膜绕线的中心附近形成以导电材料组成的第一薄膜磁芯409;也可以在第二薄膜线圈402’的第二薄膜绕线的中心部位形成有第二薄膜磁芯410。此类薄膜磁芯主要成份就是磁性材料,例如铌铁锰合金、钍锰合金、铁钴硅合金、铁铬钴合金薄膜磁芯等硬磁材料,此处的磁性材料较佳可为一种强磁性材料所形成,可增加薄膜绕线的感应电流与感应电动势或作为线圈定位用。Furthermore, according to yet another embodiment, the above-mentioned main structure formed by the first thin film coil 401', the adhesive layer 403' and the second thin film coil 402' can be formed on both sides of the spiral structure, that is, close to A first thin film magnetic core 409 made of conductive material is formed near the center of the first thin film winding of the first thin film coil 401'; thin film magnetic core 410 . The main component of this type of thin-film magnetic core is magnetic material, such as hard magnetic materials such as niobium-iron-manganese alloy, thorium-manganese alloy, iron-cobalt-silicon alloy, iron-chromium-cobalt alloy thin-film magnetic core, etc. The magnetic material here can preferably be a strong Formed by magnetic materials, it can increase the induced current and induced electromotive force of the film winding or be used for coil positioning.
图4F显示第一薄膜磁芯409形成于第一薄膜线圈401’靠近中央的表面上,制程比如贴附、电镀或是涂布;第二薄膜磁芯410形成于第二薄膜线圈402’的表面上。最后形成一薄膜线圈元件的实施例之一。FIG. 4F shows that the first thin film magnetic core 409 is formed on the surface near the center of the first thin film coil 401' by a process such as attachment, electroplating or coating; the second thin film magnetic core 410 is formed on the surface of the second thin film coil 402' superior. Finally one embodiment of a thin film coil element is formed.
更者,此例中,更可于薄膜线圈元件的外部形成一包覆元件的保护层400,除了能够强固结构,更可以绝缘以保护元件,以及防锈蚀。根据实施例,保护层400的可以由有机材料形成,其中主剂可以是:环氧树脂、丙烯酸树脂、聚氨酯树脂、压克力树脂、羧基丁腈橡胶、丁腈橡胶等;其中可混有硬化剂:脂肪族、环状脂肪族、胺类、芳香族硬化剂、光硬化剂;更可包括如氧化硅、氧化铝、氧化锆、氧化钛等的无机材料。Moreover, in this example, a protective layer 400 covering the element can be formed outside the thin film coil element. In addition to strengthening the structure, it can also insulate to protect the element and prevent corrosion. According to an embodiment, the protective layer 400 can be formed of organic materials, wherein the main agent can be: epoxy resin, acrylic resin, polyurethane resin, acrylic resin, carboxylated nitrile rubber, nitrile rubber, etc.; Agents: aliphatic, cycloaliphatic, amines, aromatic hardeners, light hardeners; it can also include inorganic materials such as silicon oxide, aluminum oxide, zirconium oxide, titanium oxide, etc.
本实用新型具有磁芯结构的薄膜线圈的实施例可参阅图5显示的示意图,此例显示由第一薄膜线圈、粘接层以及第二薄膜线圈形成的主体结构中,于螺旋结构的薄膜绕线中心部位形成有一薄膜磁芯。The embodiment of the thin film coil with magnetic core structure of the present invention can refer to the schematic diagram shown in Fig. 5. A thin-film magnetic core is formed at the central portion of the wire.
此例显示薄膜绕线501以某一螺旋方向形成薄膜线圈51,线圈外侧末端有一连接端口503,内侧则具有绕线终点507,特别的是,在线圈中间部位包括有薄膜磁芯505,此磁性物质如以上实施例所述较佳可为一种强磁性材料所形成,可增加薄膜绕线501的感应电流与感应电动势或作为线圈定位用;若组合形成薄膜线圈元件,则可分别增加第一薄膜线圈与第二薄膜线圈的感应电磁场与感应电动势,并减少涡电流损失。This example shows that the thin film winding 501 forms a thin film coil 51 in a certain helical direction. The outer end of the coil has a connection port 503, and the inner end has a winding end 507. In particular, a thin film magnetic core 505 is included in the middle of the coil. The substance can preferably be formed of a ferromagnetic material as described in the above embodiments, which can increase the induced current and induced electromotive force of the thin film winding 501 or be used as a coil positioning; if combined to form a thin film coil element, the first The induced electromagnetic field and the induced electromotive force of the thin film coil and the second thin film coil reduce eddy current loss.
图6显示本实用新型薄膜线圈元件实施例的剖面示意图。FIG. 6 shows a schematic cross-sectional view of an embodiment of the thin film coil element of the present invention.
此图例显示粘接层60为一中心结构,两侧分别形成具有一致形式的薄膜线圈51、51’,而两侧薄膜线圈51、51’的中心部位分别形成有薄膜磁芯505,505’,两侧薄膜线圈51、51’对外形成有连接端口503,503’。This figure shows that the adhesive layer 60 is a central structure, and thin-film coils 51, 51' with the same form are respectively formed on both sides, and thin-film magnetic cores 505, 505' are respectively formed in the central parts of the thin-film coils 51, 51' on both sides. The thin film coils 51, 51' are externally formed with connection ports 503, 503'.
于是,经组立两组具有薄膜磁芯505,505’的薄膜线圈51,51’后,其绕线终点507,507’即以贯穿粘接层60的导体连接部601电性相接,使得两组薄膜绕线相互串连。Therefore, after two sets of thin film coils 51, 51' with thin film magnetic cores 505, 505' are assembled, the winding end points 507, 507' are electrically connected with the conductor connection part 601 penetrating through the adhesive layer 60, so that the two sets of thin film coils are wound The lines are connected in series.
经组合一或多个薄膜线圈元件以及相关电路后,可组成如图7所示的本实用新型充电装置的实施例。After combining one or more thin film coil elements and related circuits, the embodiment of the charging device of the present invention as shown in FIG. 7 can be formed.
图例显示为一充电装置,充电装置利用一载体结合一或多个,或是多个迭层的薄膜线圈元件,载体如一个充电装置外壳,包括多个以阵列形式排列的薄膜线圈元件701,多个薄膜线圈元件701组合于一基板70上,并置入载体,一经通电,可于充电装置的表面形成均匀的感应电场,而能对安装有装置端薄膜线圈元件721的电子装置72执行充电,装置端薄膜线圈元件721即为感应由充电装置产生的感应电场,因而在装置端薄膜线圈元件721产生充电用的感应电流,进而对电子装置72内的充电电池充电,达到无线充电的目的。The illustration shows a charging device, the charging device uses a carrier to combine one or more, or a plurality of laminated thin film coil elements, the carrier is like a charging device housing, including a plurality of thin film coil elements 701 arranged in an array, multiple A thin film coil element 701 is combined on a substrate 70 and placed in a carrier. Once energized, a uniform induced electric field can be formed on the surface of the charging device, and the electronic device 72 equipped with the device end thin film coil element 721 can be charged. The thin-film coil element 721 at the device end induces the electric field generated by the charging device, so the thin-film coil element 721 at the device end generates an induced current for charging, and then charges the rechargeable battery in the electronic device 72 to achieve the purpose of wireless charging.
充电装置中主要电路比如图示的电源管理单元703,电源管理单元703电连接薄膜线圈元件701,能够界接一外部电源705,用以管理充电装置内各薄膜线圈元件701运作、输入的充电电压、元件电力配置等。薄膜线圈元件701如上述各实施例所示,各别元件包括混有磁性材料的粘接层、第一薄膜线圈以及第二薄膜线圈,粘接层特别形成为此元件的中心结构,并透过贯穿粘接层的导体连接部电连接两侧薄膜线圈,能于通电后于充电装置上形成一致方向的感应电磁场。The main circuit in the charging device is such as the power management unit 703 shown in the figure. The power management unit 703 is electrically connected to the thin film coil element 701 and can be connected to an external power supply 705 to manage the operation and input charging voltage of each thin film coil element 701 in the charging device. , Component power configuration, etc. The thin film coil element 701 is as shown in the above embodiments, each element includes an adhesive layer mixed with magnetic material, a first thin film coil and a second thin film coil, the adhesive layer is specially formed as the central structure of this element, and passes through The conductor connecting portion penetrating through the adhesive layer is electrically connected to the thin film coils on both sides, and can form an induced electromagnetic field in the same direction on the charging device after electrification.
值得一提的是,除上述说明书所描述的实施例以外,形成在粘接层两侧的薄膜线圈制作方式不排除仍可藉由溅镀、蒸镀、电镀、化学镀、涂布、凹/凸版印刷、网印、黄光制程(曝光微影蚀刻)、贴膜、转印等方式实现。It is worth mentioning that, in addition to the embodiments described in the above specification, the manufacturing method of the thin film coils formed on both sides of the adhesive layer does not exclude that sputtering, evaporation, electroplating, electroless plating, coating, concave/ Toppan printing, screen printing, yellow light process (exposure lithography), film, transfer printing and other methods to achieve.
是以,本实用新型公开的薄膜线圈元件与充电装置,由于薄型化、可挠以及立体化的设计,形成可用于无线充电的高增益立体薄膜线圈,根据说明书所载的实施例,此无基板的薄膜线圈元件的主体主要直接以粘接层作为中心结构,制程中则以薄膜导电材料为基板,最后形成螺旋形式的薄膜线圈,同时,粘接层材料可以混有磁性材料,比如铁磁颗粒,用以增加整个元件的电磁感应能力与磁场稳定性,使得薄膜线圈元件可以改善其中电磁转换效率,而更有效率地产生感应电动势或感应电流。Therefore, the thin-film coil element and the charging device disclosed in the utility model form a high-gain three-dimensional thin-film coil that can be used for wireless charging due to the thin, flexible and three-dimensional design. According to the embodiment contained in the specification, this substrate-free The main body of the thin-film coil component mainly uses the adhesive layer as the central structure directly, and the thin-film conductive material is used as the substrate in the manufacturing process, and finally forms a spiral-shaped thin-film coil. At the same time, the adhesive layer material can be mixed with magnetic materials, such as ferromagnetic particles. , to increase the electromagnetic induction capability and magnetic field stability of the entire element, so that the thin film coil element can improve the electromagnetic conversion efficiency in it, and generate induced electromotive force or induced current more efficiently.
更者,本实用新型所提出以薄膜线圈形成的线圈元件可以产生如传统铜线线圈产生感应电磁场的效果,并因为较传统铜线线圈设计的电阻耗损更小,结构较传统铜线线圈或市面上柔性线圈更加轻薄,可以有效提升单位面积的发电效率,并且可克服薄膜线圈增益不足的缺点。What's more, the coil element formed by the thin film coil proposed by the utility model can produce the effect of the induced electromagnetic field as the traditional copper wire coil, and because the resistance loss of the traditional copper wire coil design is smaller, the structure is better than the traditional copper wire coil or the market. The upper flexible coil is lighter and thinner, which can effectively improve the power generation efficiency per unit area, and can overcome the disadvantage of insufficient gain of the thin film coil.
以上所述仅为本实用新型的较佳可行实施例,凡依本实用新型申请专利范围所做的均等变化与修饰,皆应属本实用新型的涵盖范围。The above description is only a preferred feasible embodiment of the utility model, and all equal changes and modifications made according to the patent scope of the utility model shall fall within the scope of the utility model.
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CN112689798A (en) * | 2018-09-12 | 2021-04-20 | 爱泰德有限公司 | Imprint apparatus and imprint method |
CN114644899A (en) * | 2022-03-16 | 2022-06-21 | 博硕科技(江西)有限公司 | Conductive adhesive, preparation method, double-sided conductive adhesive and wireless charging module |
US12230897B2 (en) | 2020-11-16 | 2025-02-18 | Chengdu Boe Optoelectronics Technology Co., Ltd. | Circuit board assembly, display assembly and assembling method therefor, and display device |
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CN112689798A (en) * | 2018-09-12 | 2021-04-20 | 爱泰德有限公司 | Imprint apparatus and imprint method |
US12230897B2 (en) | 2020-11-16 | 2025-02-18 | Chengdu Boe Optoelectronics Technology Co., Ltd. | Circuit board assembly, display assembly and assembling method therefor, and display device |
CN114644899A (en) * | 2022-03-16 | 2022-06-21 | 博硕科技(江西)有限公司 | Conductive adhesive, preparation method, double-sided conductive adhesive and wireless charging module |
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