WO2019075668A1 - Flat coil, manufacturing method thereof and electronic apparatus - Google Patents

Flat coil, manufacturing method thereof and electronic apparatus Download PDF

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Publication number
WO2019075668A1
WO2019075668A1 PCT/CN2017/106720 CN2017106720W WO2019075668A1 WO 2019075668 A1 WO2019075668 A1 WO 2019075668A1 CN 2017106720 W CN2017106720 W CN 2017106720W WO 2019075668 A1 WO2019075668 A1 WO 2019075668A1
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WO
WIPO (PCT)
Prior art keywords
flat coil
metal foil
foil
thin disks
manufacturing
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Ceased
Application number
PCT/CN2017/106720
Other languages
French (fr)
Inventor
Quanbo Zou
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Goertek Inc
Original Assignee
Goertek Inc
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Goertek Inc filed Critical Goertek Inc
Priority to US15/739,950 priority Critical patent/US11004602B2/en
Priority to PCT/CN2017/106720 priority patent/WO2019075668A1/en
Priority to CN201780002391.2A priority patent/CN109952625A/en
Publication of WO2019075668A1 publication Critical patent/WO2019075668A1/en
Anticipated expiration legal-status Critical
Ceased legal-status Critical Current

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    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F41/00—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties
    • H01F41/02—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets
    • H01F41/04—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets for manufacturing coils
    • H01F41/06—Coil winding
    • H01F41/071—Winding coils of special form
    • H01F41/074—Winding flat coils
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F27/00—Details of transformers or inductances, in general
    • H01F27/28—Coils; Windings; Conductive connections
    • H01F27/2847—Sheets; Strips
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F27/00—Details of transformers or inductances, in general
    • H01F27/28—Coils; Windings; Conductive connections
    • H01F27/2871—Pancake coils
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F41/00—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties
    • H01F41/02—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets
    • H01F41/04—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets for manufacturing coils
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F41/00—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties
    • H01F41/02—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets
    • H01F41/04—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets for manufacturing coils
    • H01F41/041—Printed circuit coils
    • H01F41/045—Trimming
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F41/00—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties
    • H01F41/02—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets
    • H01F41/04—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets for manufacturing coils
    • H01F41/041—Printed circuit coils
    • H01F41/047—Printed circuit coils structurally combined with superconductive material
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F5/00—Coils
    • H01F5/003—Printed circuit coils
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02J—ELECTRIC POWER NETWORKS; CIRCUIT ARRANGEMENTS OR SYSTEMS FOR SUPPLYING OR DISTRIBUTING ELECTRIC POWER; SYSTEMS FOR STORING ELECTRIC ENERGY
    • H02J50/00—Circuit arrangements or systems for wireless supply or distribution of electric power
    • H02J50/005—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
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02J—ELECTRIC POWER NETWORKS; CIRCUIT ARRANGEMENTS OR SYSTEMS FOR SUPPLYING OR DISTRIBUTING ELECTRIC POWER; SYSTEMS FOR STORING ELECTRIC ENERGY
    • H02J50/00—Circuit arrangements or systems for wireless supply or distribution of electric power
    • H02J50/10—Circuit arrangements or systems for wireless supply or distribution of electric power using inductive coupling
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F27/00—Details of transformers or inductances, in general
    • H01F27/28—Coils; Windings; Conductive connections
    • H01F27/2847—Sheets; Strips
    • H01F2027/2857—Coil formed from wound foil conductor
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T29/00—Metal working
    • Y10T29/49—Method of mechanical manufacture
    • Y10T29/49002—Electrical device making
    • Y10T29/4902—Electromagnet, transformer or inductor
    • Y10T29/49073—Electromagnet, transformer or inductor by assembling coil and core
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T29/00—Metal working
    • Y10T29/49—Method of mechanical manufacture
    • Y10T29/49002—Electrical device making
    • Y10T29/49108—Electric battery cell making

Definitions

  • the present invention relates to the technical field of forming coil, more specifically, to a method for manufacturing a flat coil, a flat coil and an electronic apparatus.
  • a wireless charging unit includes at least one flat coil. It is desired that the flat coil has a high quality and/or efficiency, at reasonably low cost.
  • Fig. 1 shows a Cu wire coil.
  • a flat coil 12 is formed by wingding a Cu wire.
  • the flat coil 12 is placed on a ferrite sheet 14 via an adhesive tape 13.
  • a magnet core 11 is provided to the flat coil 12. Since the flat coil is formed by winding a Cu wire, its through-put is relatively low and its cost is relatively high. Besides, the shape and diameters of the Cu wire are limited. So, it is difficult to perform a design optimization.
  • a flat coil on a printed circuit board, for example, by lithography, Cu etching or plating on a PCB (Printed Circuitry Board) , FPCB (Flexible Printed Circuitry Board) or ceramic substrates.
  • Fig. 2 shows a schematic diagram of a flat coil in a PCB. As shown in Fig. 2, a coil array 22 is formed between an interface surface 21 and a shielding layer 23. This approach may suffer manufacturing cost issue. Furthermore, the flat coil manufactured by this approach typically has a degraded performance. For example, it has a high resistance, a low Quality-factor and a low efficiency.
  • One object of this invention is to provide a new technical solution for a flat coil.
  • a method for manufacturing a flat coil comprising: rolling a metal foil lamination onto a carrier roller to form a foil rod, wherein the metal foil lamination includes at least one layer of metal foil; sliding the foil rod from the carrier roller; slicing the foil rod into thin disks; and processing the thin disks to form at least one flat coil.
  • the carrier roller has a starting slit, and one end of the metal foil lamination is inserted and fixed in the starting slit.
  • a pressing roller is pressed against the carrier roller via the metal foil lamination with a controlled pressing force during the metal foil lamination is rolled.
  • the metal foil lamination includes at least two layers of metal foils.
  • processing the thin disks further comprises: grinding the thin disks to a preset thickness; coating the thin disks with a passivation layer; and forming terminals of the thin disks.
  • the metal foil is a Cu foil.
  • the foil rod is sliced by using at least one of blade dicing, wire cutting and wire electrical discharging machining.
  • the metal foil contains an insulation layer with adhesive.
  • a flat coil manufactured by using the method for manufacturing a flat coil according to any of the embodiments of this disclosure.
  • a n electronic apparatus comprising a wireless charging unit which includes at least one flat coil according to any of the embodiments of this disclosure.
  • a new solution for manufacturing a flat coil is proposed. It may lower the manufacturing cost and/or provide a relatively high performance.
  • Fig. 1 is a schematic diagram of a flat coil manufactured by a prior art approach.
  • Fig. 2 is a schematic diagram of a flat coil manufactured by another prior art approach.
  • Fig. 3-8 show a schematic diagram of a process of manufacturing a flat coil according to an embodiment of this disclosure.
  • Fig. 9 shows a schematic diagram of a flat coil manufactured according to another embodiment of this disclosure.
  • the embodiments of this disclosure propose a new approach of manufacturing a flat coil, which is different from the prior art.
  • metal foils are used to manufacturing a flat coil. Compared with the prior art, this approach is more easy and/or cost-efficient.
  • Fig. 3-8 show a schematic diagram of a process of manufacturing a flat coil according to an embodiment of this disclosure.
  • Fig. 3 shows that a metal foil lamination 301 is rolled onto a carrier roller 304 to form a foil rod.
  • the metal foil lamination 301 includes at least one layer of metal foil 302.
  • the metal foil is a Cu foil 302.
  • Fig. 9 shows a metal foil lamination 301m, which includes at least two layers of metal foils.
  • the metal foil 302 contains an insulation layer 303 with adhesive.
  • the carrier roller 304 has a starting slit 305, and one end of the metal foil lamination 301 is inserted and fixed in the starting slit 305.
  • the carrier roller 304 may not be round, and may have a cross-section of other shape. This approach may provide a designer with more freedom of design.
  • a pressing roller 306 is pressed against the carrier roller 304 via the metal foil lamination 301 with a controlled pressing force during the metal foil lamination 301 is rolled.
  • the metal foil lamination 301 travels in the direction A
  • the carrier roller 304 rotates in the direction C
  • the pressing roller 306 rotates in the direction B, as shown in Fig. 3.
  • the metal foil lamination 301 is rolled into a foil rod.
  • the foil rod 308 is slid from the carrier roller 304.
  • the length of the foil rod 308 is L, which is much larger than the length of a single flat coil.
  • the foil rod 308 can be used to make multiple flat coils.
  • the end 307 of the metal foil lamination 301 is one inserted in the starting slit 305, as shown in Figs. 3 and 4.
  • the foil rod 308 is sliced into thin disks 309.
  • the thin disk 309 is annular, for example.
  • the thickness of a sliced thin disk may be from 100 ⁇ m to 1000 ⁇ m, for example.
  • the foil rod 308 is sliced by using at least one of blade dicing, wire cutting and wire electrical discharging machining.
  • the thin disks 309 are processed to form at least one flat coil.
  • a person skilled in the art can conceive a lot processes for the thin disks 309.
  • the sliced thin disks 309 may be placed on a large platform for processing, as shown in Fig. 7.
  • the processing may include: grinding the thin disks to a preset thickness; coating the thin disks with a passivation layer; and forming terminals of the thin disks.
  • the thickness of a grinded thin disk may be from 50 ⁇ m to 900 ⁇ m and the passivation layer on the grinded surfaces of the flat coil (such as a Cu coil) is 5-25 ⁇ m.
  • the passivation layer can be polymer, plastic, epoxy, resist, adhesive and/or glue.
  • Fig. 8 shows a finished flat coil 311.
  • the flat coil 311 is manufactured from the metal foil lamination 301.
  • the flat coil 311 has a first terminal 312 and a second terminal 313.
  • the terminals 312, 313 may be formed by laser trimming or lithography patterning.
  • Fig. 9 shows a schematic diagram of a flat coil 311m manufactured according to another embodiment of this disclosure.
  • the flat coil 311m is manufactured from the metal foil lamination 301m, which has at least two layers of metal foils.
  • the flat coil 311m has a first terminal 312m and a second terminal 313m.
  • a flat coil manufactured by using the method for manufacturing a flat coil according to any of the above embodiments may also be provided.
  • the flat coil may be used in a wireless charging unit of an electronic apparatus.
  • the flat coil may be used to replace the flat coil 12 in Fig. 1.
  • an electronic apparatus comprises a wireless charging unit, and the wireless charging unit includes at least one flat coil according to according to any of the above embodiments.
  • the electronic apparatus may be smart phone, an electronic tooth-brush, and so on.

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  • Engineering & Computer Science (AREA)
  • Power Engineering (AREA)
  • Manufacturing & Machinery (AREA)
  • Computer Networks & Wireless Communication (AREA)
  • Coils Or Transformers For Communication (AREA)
  • Windings For Motors And Generators (AREA)
  • Manufacture Of Motors, Generators (AREA)

Abstract

A flat coil(311), a manufacturing method thereof and an electronic apparatus are disclosed. The manufacturing method comprises: rolling a metal foil lamination(301) onto a carrier roller(304) to form a foil rod(308), wherein the metal foil lamination(301) includes at least one layer of metal foil(302); sliding the foil rod(308) from the carrier roller(304); slicing the foil rod(308) into thin disks(309); and processing the thin disks(309) to form at least one flat coil(311). According to this disclosure, a new solution for a flat coil(311) is proposed.

Description

[Title established by the ISA under Rule 37.2] FLAT COIL, MANUFACTURING METHOD THEREOF AND ELECTRONIC APPARATUS FIELD OF THE INVENTION
The present invention relates to the technical field of forming coil, more specifically, to a method for manufacturing a flat coil, a flat coil and an electronic apparatus.
BACKGROUND OF THE INVENTION
Recently, wireless charging applications become more and more attractive. Some of the leading smart phone suppliers have adopted wireless charging units in their smart phones. Other electronic apparatus such as wearable apparatus, handheld apparatus, computers and so on are also starting to adopt wireless charging unit. Generally, a wireless charging unit includes at least one flat coil. It is desired that the flat coil has a high quality and/or efficiency, at reasonably low cost.
In the prior art, there are two approaches for manufacturing a flat coil.
One approach is a Cu wire winding approach. Fig. 1 shows a Cu wire coil. As shown in Fig. 1, a flat coil 12 is formed by wingding a Cu wire. The flat coil 12 is placed on a ferrite sheet 14 via an adhesive tape 13. A magnet core 11 is provided to the flat coil 12. Since the flat coil is formed by winding a Cu wire, its through-put is relatively low and its cost is relatively high. Besides, the shape and diameters of the Cu wire are limited. So, it is difficult to perform a design optimization.
The other approach is to form a flat coil on a printed circuit board, for example, by lithography, Cu etching or plating on a PCB (Printed Circuitry Board) , FPCB (Flexible Printed Circuitry Board) or ceramic substrates. Fig. 2 shows a schematic diagram of a flat coil in a PCB. As shown in Fig. 2, a coil array 22 is formed between an interface surface 21 and a shielding layer 23. This approach may suffer manufacturing cost issue. Furthermore, the flat coil manufactured by this approach typically has a degraded performance. For example, it has a high resistance, a low Quality-factor and a low efficiency.
Therefore, there is a demand in the art that a new solution for manufacturing a flat coil  shall be proposed to address at least one of the problems in the prior art.
SUMMARY OF THE INVENTION
One object of this invention is to provide a new technical solution for a flat coil.
According to a first aspect of the present invention, there is provided a method for manufacturing a flat coil, comprising: rolling a metal foil lamination onto a carrier roller to form a foil rod, wherein the metal foil lamination includes at least one layer of metal foil； sliding the foil rod from the carrier roller； slicing the foil rod into thin disks； and processing the thin disks to form at least one flat coil.
Alternatively or optionally, the carrier roller has a starting slit, and one end of the metal foil lamination is inserted and fixed in the starting slit.
Alternatively or optionally, a pressing roller is pressed against the carrier roller via the metal foil lamination with a controlled pressing force during the metal foil lamination is rolled.
Alternatively or optionally, the metal foil lamination includes at least two layers of metal foils.
Alternatively or optionally, processing the thin disks further comprises: grinding the thin disks to a preset thickness； coating the thin disks with a passivation layer； and forming terminals of the thin disks.
Alternatively or optionally, the metal foil is a Cu foil.
Alternatively or optionally, the foil rod is sliced by using at least one of blade dicing, wire cutting and wire electrical discharging machining.
Alternatively or optionally, the metal foil contains an insulation layer with adhesive.
According to a second aspect of the present invention, there is provided a flat coil manufactured by using the method for manufacturing a flat coil according to any of the embodiments of this disclosure.
According to a third aspect of the present invention, there is provided a n electronic apparatus comprising a wireless charging unit which includes at least one flat coil according to any of the embodiments of this disclosure.
According to an embodiment of this disclosure, a new solution for manufacturing a flat  coil is proposed. It may lower the manufacturing cost and/or provide a relatively high performance.
Further features of the present invention and advantages thereof will become apparent from the following detailed description of exemplary embodiments according to the present invention with reference to the attached drawings.
BRIEF DISCRIPTION OF THE DRAWINGS
The accompanying drawings, which are incorporated in and constitute a part of the specification, illustrate embodiments of the invention and, together with the description thereof, serve to explain the principles of the invention.
Fig. 1 is a schematic diagram of a flat coil manufactured by a prior art approach.
Fig. 2 is a schematic diagram of a flat coil manufactured by another prior art approach.
Fig. 3-8 show a schematic diagram of a process of manufacturing a flat coil according to an embodiment of this disclosure.
Fig. 9 shows a schematic diagram of a flat coil manufactured according to another embodiment of this disclosure.
DETAILED DESCRIPTION OF THE EMBODIMENTS
Various exemplary embodiments of the present invention will now be described in detail with reference to the drawings. It should be noted that the relative arrangement of the components and steps, the numerical expressions, and numerical values set forth in these embodiments do not limit the scope of the present invention unless it is specifically stated otherwise.
The following description of at least one exemplary embodiment is merely illustrative in nature and is in no way intended to limit the invention, its application, or uses.
Techniques, methods and apparatus as known by one of ordinary skill in the relevant art may not be discussed in detail but are intended to be part of the specification where appropriate.
In all of the examples illustrated and discussed herein, any specific values should be  interpreted to be illustrative only and non-limiting. Thus, other examples of the exemplary embodiments could have different values.
Notice that similar reference numerals and letters refer to similar items in the following figures, and thus once an item is defined in one figure, it is possible that it need not be further discussed for following figures.
Embodiments and examples will be described with reference to the figures.
The embodiments of this disclosure propose a new approach of manufacturing a flat coil, which is different from the prior art. In the embodiments, metal foils are used to manufacturing a flat coil. Compared with the prior art, this approach is more easy and/or cost-efficient.
Fig. 3-8 show a schematic diagram of a process of manufacturing a flat coil according to an embodiment of this disclosure.
Fig. 3 shows that a metal foil lamination 301 is rolled onto a carrier roller 304 to form a foil rod.
The metal foil lamination 301 includes at least one layer of metal foil 302. For example, the metal foil is a Cu foil 302. Fig. 9 shows a metal foil lamination 301m, which includes at least two layers of metal foils. For example, the metal foil 302 contains an insulation layer 303 with adhesive.
As shown in Fig. 3, the carrier roller 304 has a starting slit 305, and one end of the metal foil lamination 301 is inserted and fixed in the starting slit 305.
Here, the carrier roller 304 may not be round, and may have a cross-section of other shape. This approach may provide a designer with more freedom of design.
Also as shown in Fig. 3, a pressing roller 306 is pressed against the carrier roller 304 via the metal foil lamination 301 with a controlled pressing force during the metal foil lamination 301 is rolled. During the rolling, the metal foil lamination 301 travels in the direction A, the carrier roller 304 rotates in the direction C, and the pressing roller 306 rotates in the direction B, as shown in Fig. 3.
As shown in Fig. 4, the metal foil lamination 301 is rolled into a foil rod.
As shown in Fig. 5, the foil rod 308 is slid from the carrier roller 304. For example, the length of the foil rod 308 is L, which is much larger than the length of a single flat coil. The foil  rod 308 can be used to make multiple flat coils. The end 307 of the metal foil lamination 301 is one inserted in the starting slit 305, as shown in Figs. 3 and 4.
As shown in Fig. 6, the foil rod 308 is sliced into thin disks 309. The thin disk 309 is annular, for example. The thickness of a sliced thin disk may be from 100μm to 1000μm, for example.
For example, the foil rod 308 is sliced by using at least one of blade dicing, wire cutting and wire electrical discharging machining.
Next, the thin disks 309 are processed to form at least one flat coil. Under the teaching of this disclosure, a person skilled in the art can conceive a lot processes for the thin disks 309.
For example, the sliced thin disks 309 may be placed on a large platform for processing, as shown in Fig. 7. The processing may include: grinding the thin disks to a preset thickness； coating the thin disks with a passivation layer； and forming terminals of the thin disks.
For example, the thickness of a grinded thin disk may be from 50μm to 900μm and the passivation layer on the grinded surfaces of the flat coil (such as a Cu coil) is 5-25μm. For example, the passivation layer can be polymer, plastic, epoxy, resist, adhesive and/or glue.
Fig. 8 shows a finished flat coil 311. The flat coil 311 is manufactured from the metal foil lamination 301. The flat coil 311 has a first terminal 312 and a second terminal 313. For example, the  terminals  312, 313 may be formed by laser trimming or lithography patterning.
Fig. 9 shows a schematic diagram of a flat coil 311m manufactured according to another embodiment of this disclosure. The flat coil 311m is manufactured from the metal foil lamination 301m, which has at least two layers of metal foils. The flat coil 311m has a first terminal 312m and a second terminal 313m.
According to another embodiment of this disclosure, a flat coil manufactured by using the method for manufacturing a flat coil according to any of the above embodiments may also be provided. The flat coil may be used in a wireless charging unit of an electronic apparatus. For example, the flat coil may be used to replace the flat coil 12 in Fig. 1.
According to still another embodiment of this disclosure, an electronic apparatus is provided. The electronic apparatus comprises a wireless charging unit, and the wireless charging  unit includes at least one flat coil according to according to any of the above embodiments. The electronic apparatus may be smart phone, an electronic tooth-brush, and so on.
Although some specific embodiments of the present invention have been demonstrated in detail with examples, it should be understood by a person skilled in the art that the above examples are only intended to be illustrative but not to limit the scope of the present invention.

Claims (10)

  1. A method for manufacturing a flat coil, comprising:
    rolling a metal foil lamination onto a carrier roller to form a foil rod, wherein the metal foil lamination includes at least one layer of metal foil；
    sliding the foil rod from the carrier roller；
    slicing the foil rod into thin disks； and
    processing the thin disks to form at least one flat coil.
  2. The method according to claim 1, wherein the carrier roller has a starting slit, and one end of the metal foil lamination is inserted and fixed in the starting slit.
  3. The method according to claim 1 or 2, wherein a pressing roller is pressed against the carrier roller via the metal foil lamination with a controlled pressing force during the metal foil lamination is rolled.
  4. The method according to any of claims 1-3, wherein the metal foil lamination includes at least two layers of metal foils.
  5. The method according to any of claims 1-4, wherein processing the thin disks further comprises:
    grinding the thin disks to a preset thickness；
    coating the thin disks with a passivation layer； and
    forming terminals of the thin disks.
  6. The method according to any of claims 1-5, wherein the metal foil is a Cu foil.
  7. The method according to any of claims 1-6, wherein the foil rod is sliced by using at least one of blade dicing, wire cutting and wire electrical discharging machining.
  8. The method according to any of claims 1-7, wherein the metal foil contains an insulation layer with adhesive.
  9. A flat coil manufactured by using the method for manufacturing a flat coil according to any of claims 1-8.
  10. An electronic apparatus comprising a wireless charging unit which includes at least one flat coil according to claim 9.
PCT/CN2017/106720 2017-10-18 2017-10-18 Flat coil, manufacturing method thereof and electronic apparatus Ceased WO2019075668A1 (en)

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US15/739,950 US11004602B2 (en) 2017-10-18 2017-10-18 Manufacturing method of flat coil and electronic apparatus
PCT/CN2017/106720 WO2019075668A1 (en) 2017-10-18 2017-10-18 Flat coil, manufacturing method thereof and electronic apparatus
CN201780002391.2A CN109952625A (en) 2017-10-18 2017-10-18 Flat coil, its manufacturing method and electronic device

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CN112320465A (en) * 2020-11-06 2021-02-05 刘杰 Energy-saving environment-friendly wire conveying adjusting device for coil panel of induction cooker

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JPH05207710A (en) * 1992-01-21 1993-08-13 Sankyo Seiki Mfg Co Ltd Manufacture of thin coil
JP2000223343A (en) * 1999-02-03 2000-08-11 Mitsubishi Materials Corp Method for manufacturing flat coil having magnetic core member and jig for winding the same
CN201749754U (en) * 2010-08-04 2011-02-16 北京美新华微电子技术有限公司 Wireless power transmission coil
CN103400682A (en) * 2013-08-14 2013-11-20 广西电网公司电力科学研究院 Magnetic core structure and electromagnetic coupling device based on magnetic core structure

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CN109952625A (en) 2019-06-28
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