WO2019169707A1

WO2019169707A1 - Laser cutting manufacturing process for wireless charging coil

Info

Publication number: WO2019169707A1
Application number: PCT/CN2018/084480
Authority: WO
Inventors: 肖聪雨
Original assignee: 东莞领益精密制造科技有限公司
Priority date: 2018-03-07
Filing date: 2018-04-25
Publication date: 2019-09-12
Also published as: CN108511181B; CN108511181A

Abstract

A laser cutting manufacturing process for a wireless charging coil, comprising the following steps: perform preliminary laser cutting on a copper foil, the preliminary laser cutting only being used for cutting partial areas of the copper foil, and arc-shaped copper wires being cut on the copper foil (S1); perform subsequent laser cutting on the copper foil, the subsequent laser cutting being used for cutting another partial areas of the copper foil, and the arc-shaped copper wires being cut on the copper foil (S2); the arc-shaped copper wires cut by means of the preliminary laser cutting and the arc-shaped copper wires cut by means of the subsequent laser cutting form a continuous spiral coil (S3). According to the manufacturing process, the arc-shaped copper wires cut by means of the primary laser cutting are basically kept on one plane with the copper foil, namely, no severe vertical falling phenomenon occurs, and therefore, operations such as rotating, conveying, or laminating can be carried out conveniently; then, the subsequent laser cutting is performed, the subsequent laser cutting is used for cutting another partial areas of the copper foil, and the arc-shaped copper wires cut by means of the preliminary laser cutting and the arc-shaped copper wires cut by means of the subsequent laser cutting form the continuous spiral coil, so as to realize manufacturing of the wireless charging coil.

Description

Wireless charging coil laser cutting manufacturing process

Technical field

The present invention relates to the field of wireless charging coil manufacturing, and more particularly to a wireless charging coil laser cutting manufacturing process.

Background technique

The existing coil processing adopts a copper wire winding method, which has poor dimensional accuracy and low efficiency, and cannot meet the technical requirements of the wireless charging coil.

There are also some new wireless charging coil manufacturing methods, such as the Chinese invention patent disclosed in CN104465067A, which discloses a method for manufacturing a wireless charging coil, comprising the following steps: 1) preparing a plastic part; preparing a laser-activated method 2) spraying a layer of the laser-activated coating on the front and back areas of the plastic part; 3) using a laser to laser the spiral coil groove and the feed point groove on the front side of the plastic part, at the inner end point And a through hole is arranged on the second feeding point slot; and the laser is used to laser the pattern groove on the back surface of the plastic part; 4) the cleaning step 3) the processed plastic part; 5) sequentially performing the groove on the surface of the plastic part Electroless copper plating, electrical copper plating treatment. The method pre-sets the spiral coil groove and the feed point groove, and then forms a copper layer in the spiral coil groove and the feed point groove by using electroless copper plating or electrical copper plating, thereby finally forming a wireless charging coil. However, this method still has shortcomings, and the manufacturing method is very complicated. The electroless copper plating or the electroless copper plating is complicated in operation and is prone to pollution. At the same time, the spiral coil slot and the feed point slot must have a certain wall thickness, which results in a large gap between the charging coils, and the final product charging efficiency is not high.

Summary of the invention

It is an object of the present invention to provide a wireless charging coil laser cutting manufacturing process that can address one or more of the above prior art problems.

According to an aspect of the present invention, a wireless charging coil laser cutting manufacturing process is provided, as follows;

The copper foil is subjected to preliminary laser cutting, and the preliminary laser cutting only cuts a part of the copper foil, and the curved copper wire is cut on the copper foil;

The copper foil is subjected to subsequent laser cutting, and subsequent laser cutting cuts a part of the copper foil, and cuts the curved copper wire on the copper foil;

The arc-shaped copper wire cut by the preliminary laser forms a continuous spiral coil with the arc-shaped copper wire cut by the subsequent laser.

The utility model has the advantages that the laser cutting of the sheet-shaped copper foil is directly performed, and the cutting can be performed by infrared light or ultraviolet light, and the copper foil is stepwise cut during the cutting process, and only the copper foil is used for the preliminary laser cutting. Part of the area is cut, the degree of initial laser cutting, as far as possible, the arc-shaped copper wire cut out by the preliminary laser is suspended in the state of the copper foil, and the arc-shaped copper wire cut by the preliminary laser is basically kept on a plane with the copper foil itself, that is, There is no serious drooping, so that it is easy to rotate, transport or film. Then, the subsequent laser cutting is performed, and in the subsequent laser cutting, another part of the copper foil is cut, and the arc-shaped copper wire cut by the preliminary laser and the arc-shaped copper wire cut by the subsequent laser form a continuous spiral coil, thereby realizing The manufacture of wireless charging coils.

Since the present invention is directly produced by laser cutting, the cutting precision can be very high, and the precision of 0.05 mm can be achieved.

The initial laser cutting and subsequent laser cutting can be carried out by the same laser station. After the initial laser cutting, after rotating the copper foil, another area of the copper foil is subjected to subsequent laser cutting. Or directly let the laser station rotate the angle to perform subsequent laser cutting on another area of the copper foil.

In general, the present invention prefers to perform preliminary laser cutting and subsequent laser cutting, respectively, using different laser stations.

In some embodiments, the copper foil to be cut is divided into four quadrant regions, and only the first quadrant and the third quadrant are cut during preliminary laser cutting, and the second quadrant and the fourth quadrant are cut during subsequent laser cutting. By means of misalignment cutting, when the initial laser cutting is performed, only the copper foils of the first quadrant and the third quadrant are laser-cut to produce a preliminary laser-cut arc-shaped copper wire, which is only one quarter of a circle. The size, so there is basically no drooping phenomenon, which can ensure that the arc-shaped copper wire cut by the preliminary laser is still substantially in the same plane as the copper foil. If it is directly divided into two semi-circular areas, a shallow semi-circular area is cut directly during the initial laser cutting, which may cause a certain drooping phenomenon.

It is of course also possible to divide the entire circle into three equal division areas, thereby performing a preliminary laser cutting and two subsequent laser cuttings, and cutting the entire charging coil by three cuttings. Or directly octave, and number 8 aliquots are numbered 1, 2, 3, 4, 5, 6, 7, and 8. During the initial laser cutting, preliminary laser cutting is performed on the four areas of 1, 3, 5, and 7. After the subsequent laser cutting, the subsequent laser cutting is performed on the four areas of 2, 4, 6, and 8. Relatively speaking, the more the number of parts is divided, the smaller the arc-shaped copper wire cut by the initial laser can be prevented from falling.

In some embodiments, prior to the preliminary laser cutting, the copper foil is rolled copper, pulled through a puller, and continuously conveyed for preliminary laser cutting.

In some embodiments, the first station is configured to perform preliminary laser cutting of the copper foil, and the second station is configured to perform subsequent laser cutting of the copper foil. The copper foil is cut by two stations, so that continuous processing can be realized, and the above-mentioned rolled copper material can be pulled out by the puller, thereby realizing automatic production.

In some embodiments, in order to better prevent the arcuate copper wire cut by the preliminary laser from falling, the preliminary laser-cut copper foil may be coated between the preliminary laser cutting and the subsequent laser cutting. If the film is not coated, the entire cut coil is completely suspended at the moment when the subsequent laser cutting is completely finished. There is no supporting force next to it, and it is particularly prone to drooping, but by preliminary laser cutting and subsequent laser cutting. After coating the copper foil with a film, it can ensure that the whole copper foil can be supported by the film. After the initial laser cutting, only the arc-shaped copper wire which is partially cut by the preliminary laser is suspended, but the film is covered. After that, the arc-shaped copper wire cut by the preliminary laser is supported by the coating film, and after the laser cutting, a part of the area is cut, and the film at the corresponding position is also cut off. The arc-shaped copper wire cut by the subsequent laser is now suspended. That is, after the film is coated, it can be ensured that the arc-shaped copper wire cut by the preliminary laser and the arc-shaped copper wire cut by the subsequent laser are simply suspended, and will not be completely suspended, thereby ensuring that the entire coil does not fall seriously.

In some embodiments, the scrap is removed after subsequent laser cutting of the copper foil. The waste generated by subsequent laser cutting is excluded.

In some embodiments, the cut spiral coil is subjected to a baking varnish operation, and the gap between the coils is filled with an insulating varnish. Since the laser cutting process can be very precise, the gap between the copper wires of the coil can reach an accuracy of 0.05 mm, so that the conduction short circuit is easily generated, and the short circuit can be prevented by performing the baking varnish operation on the spiral coil. Occurs to ensure the normal use of the product.

In some embodiments, the plurality of helical coils that are laser cut are stacked in series horizontally or vertically. When the charging coils are officially used, they are often stacked in series horizontally or vertically, thereby achieving higher charging efficiency.

In some embodiments, the lamination operation is performed by a third station, and after subsequent laser cutting, the film is removed.

In some embodiments, the inner hole and profile of the wireless charging coil are continuously laser processed after subsequent laser cutting of the copper foil. The result is a formal wireless charging coil product.

DRAWINGS

1 is a schematic flow chart of a laser cutting manufacturing process of a wireless charging coil according to an embodiment of the present invention;

2 is a schematic view showing a cutting effect of a laser cutting manufacturing process of a wireless charging coil according to an embodiment of the present invention.

3 is a schematic view showing a production line of a laser cutting manufacturing process of a wireless charging coil according to an embodiment of the present invention.

4 is a schematic flow chart of a laser cutting manufacturing process of a wireless charging coil according to still another embodiment of the present invention.

Detailed ways

The invention will now be described in further detail with reference to the accompanying drawings.

1 to 4 schematically show the present invention. The wireless charging coil laser cutting manufacturing process of an embodiment shown in FIG. 1 includes the following steps;

Step S1: performing preliminary laser cutting on the copper foil, and preliminary laser cutting only cuts a part of the copper foil, and cutting the curved copper wire on the copper foil;

Step S2: performing subsequent laser cutting on the copper foil, and subsequently cutting a further portion of the copper foil by laser cutting, and cutting the curved copper wire on the copper foil;

Step S3: the arc-shaped copper wire cut by the preliminary laser and the arc-shaped copper wire cut by the subsequent laser form a continuous spiral coil.

Laser cutting directly on the sheet-like copper foil, which can be cut by infrared light or ultraviolet light. During the cutting process, the copper foil is stepwise cut. When the laser cutting is performed, only part of the copper foil is cut. The degree of initial laser cutting, as far as possible, the arc-shaped copper wire cut out by the preliminary laser in the state in which the copper foil is suspended, the arc-shaped copper wire cut by the preliminary laser can be kept on a plane substantially with the copper foil itself, that is, no serious occurrence occurs. The drooping phenomenon makes it easy to rotate, transport or film. Then, the subsequent laser cutting is performed, and in the subsequent laser cutting, another part of the copper foil is cut, and the arc-shaped copper wire cut by the preliminary laser and the arc-shaped copper wire cut by the subsequent laser form a continuous spiral coil, thereby realizing The manufacture of wireless charging coils.

The initial laser cutting and subsequent laser cutting can be carried out by the same laser station. After the initial laser cutting, the copper foil is rotated and subsequent laser cutting is performed on another area of the copper foil. Or directly let the laser station rotate the angle to perform subsequent laser cutting on another area of the copper foil.

In general, as shown in FIG. 3, the present invention is more inclined to perform preliminary laser cutting and subsequent laser cutting using different laser stations.

As shown in FIG. 2, the copper foil to be cut can be divided into four quadrant regions, and only the first quadrant and the third quadrant are cut during the preliminary laser cutting, and the second quadrant and the fourth quadrant are cut after the subsequent laser cutting. . By means of misalignment cutting, when the initial laser cutting is performed, only the copper foils of the first quadrant and the third quadrant are laser-cut to produce a preliminary laser-cut arc-shaped copper wire, which is only one quarter of a circle. The size, so there is basically no drooping phenomenon, which can ensure that the arc-shaped copper wire cut by the preliminary laser is still substantially in the same plane as the copper foil. If it is directly divided into two semi-circular areas, a shallow semi-circular area is cut directly during the initial laser cutting, which may cause a certain drooping phenomenon.

It is of course also possible to divide the entire circle into three equal division areas, thereby performing a preliminary laser cutting and two subsequent laser cuttings, and cutting the entire charging coil by three cuttings. Or directly octave, and number 8 aliquots are numbered 1, 2, 3, 4, 5, 6, 7, and 8. During the initial laser cutting, preliminary laser cutting is performed on the four areas of 1, 3, 5, and 7. After the subsequent laser cutting, the subsequent laser cutting is performed on the four areas of 2, 4, 6, and 8. Relatively speaking, the more the number of parts divided, the more the arc-shaped copper wire cut by the initial laser can be prevented from falling down.

As shown in FIGS. 3 and 4, step S0 is further included: before the preliminary laser cutting, the copper foil is a rolled copper material, which is pulled out by the puller 101, and the continuous conveyance is performed for preliminary laser cutting.

As shown in FIG. 3, the first station 102 is arranged to perform preliminary laser cutting on the copper foil, and the second station 104 is arranged to perform subsequent laser cutting on the copper foil. The copper foil is cut by two stations, so that continuous processing can be realized, and the above-described rolled copper material 100 is pulled out by the puller 101, so that automatic production can be realized.

Generally, as shown in FIGS. 3 and 4, in order to better prevent the arcuate copper wire cut by the preliminary laser from falling, step S11 may be performed: between the preliminary laser cutting and the subsequent laser cutting, the copper foil after the preliminary laser cutting Lamination is carried out. If the film is not coated, the entire cut coil is completely suspended at the moment when the subsequent laser cutting is completely finished. There is no supporting force next to it, and it is particularly prone to drooping, but by preliminary laser cutting and subsequent laser cutting. After coating the copper foil with a film, it can ensure that the whole copper foil can be supported by the film. After the initial laser cutting, only the arc-shaped copper wire which is partially cut by the preliminary laser is suspended, but the film is covered. After that, the arc-shaped copper wire cut by the preliminary laser is supported by the coating film, and after the laser cutting, a part of the area is cut, and the film at the corresponding position is also cut off. The arc-shaped copper wire cut by the subsequent laser is now suspended. That is, after the film is coated, it can be ensured that the arc-shaped copper wire cut by the preliminary laser and the arc-shaped copper wire cut by the subsequent laser are simply suspended, and will not be completely suspended, thereby ensuring that the entire coil does not fall seriously.

At the same time, the scrap is removed after the subsequent laser cutting of the copper foil. The waste generated by subsequent laser cutting is excluded.

As shown in FIG. 4, the method further includes the step S4: performing a baking varnish operation on the cut spiral coil, and filling the gap between the coils with the insulating varnish. Since the laser cutting process can be very precise, the gap between the copper wires of the coil can reach an accuracy of 0.05 mm, so that the conduction short circuit is easily generated, and the short circuit can be prevented by performing the baking varnish operation on the spiral coil. Occurs to ensure the normal use of the product. The baking varnish operation can be directly performed by setting the paint station 105 on the line shown in Fig. 3, or it can be carried out separately for the subsequent operation, and the baking varnish operation is performed separately.

When the product 106 is finally formed, the plurality of helical coils formed by laser cutting may be stacked in series horizontally or vertically. When the charging coils are officially used, they are often stacked in series horizontally or vertically, thereby achieving higher charging efficiency.

As shown in FIG. 3, the filming operation is performed by the third station 103, and after the subsequent laser cutting, the film is removed.

At the same time, it is also possible to continue laser processing of the inner hole and shape of the wireless charging coil after the subsequent laser cutting of the copper foil. As a result, a formal wireless charging coil product is finally formed, and a packaging film can be covered on the final formal wireless charging coil product, thereby facilitating transportation and subsequent pick-and-place installation operations.

The wireless charging coil specification parameters that can be realized by the manufacturing process of the present invention are as follows:

The above are only some embodiments of the invention. It will be apparent to those skilled in the art that various modifications and improvements can be made without departing from the spirit and scope of the invention.

Claims

Wireless charging coil laser cutting manufacturing process, characterized in that;

The copper foil is subjected to preliminary laser cutting, and the preliminary laser cutting only cuts a part of the copper foil, and the curved copper wire is cut on the copper foil;

The copper foil is subjected to subsequent laser cutting, and subsequent laser cutting cuts a part of the copper foil, and cuts the curved copper wire on the copper foil;

The arc-shaped copper wire cut by the preliminary laser forms a continuous spiral coil with the arc-shaped copper wire cut by the subsequent laser.
The wireless charging coil laser cutting manufacturing process according to claim 1, wherein the copper foil to be cut is divided into four quadrant regions, and only the first quadrant and the third quadrant are cut during preliminary laser cutting, and subsequent laser cutting is performed. The second quadrant and the fourth quadrant are then cut.
The wireless charging coil laser cutting manufacturing process according to claim 1, wherein the first station is provided to perform preliminary laser cutting on the copper foil, and the second station is arranged to perform subsequent laser cutting on the copper foil.
The wireless charging coil laser cutting manufacturing process according to claim 1, wherein the preliminary laser-cut copper foil is coated between the preliminary laser cutting and the subsequent laser cutting.
The wireless charging coil laser cutting manufacturing process according to claim 1, further comprising the steps of:

The copper foil is a rolled copper material which is pulled out by a puller and continuously conveyed for preliminary laser cutting.
The wireless charging coil laser cutting manufacturing process according to claim 1, wherein the scrap is removed after subsequent laser cutting of the copper foil.
The wireless charging coil laser cutting manufacturing process according to claim 1, wherein the cut spiral coil is subjected to a baking varnish operation, and the gap between the coils is filled with the insulating varnish.
The wireless charging coil laser cutting manufacturing process according to claim 1, wherein the plurality of helical coils formed by laser cutting are horizontally connected in series or vertically stacked.
The wireless charging coil laser cutting manufacturing process according to claim 4, wherein the laminating operation is performed by the third station, and the film is removed after the subsequent laser cutting.
The wireless charging coil laser cutting manufacturing process according to claim 1, wherein the inner hole and the outer shape of the wireless charging coil are continuously processed by laser after the subsequent laser cutting of the copper foil.