WO2019169708A1 - 无线充电线圈制造工艺 - Google Patents

无线充电线圈制造工艺 Download PDF

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Publication number
WO2019169708A1
WO2019169708A1 PCT/CN2018/084481 CN2018084481W WO2019169708A1 WO 2019169708 A1 WO2019169708 A1 WO 2019169708A1 CN 2018084481 W CN2018084481 W CN 2018084481W WO 2019169708 A1 WO2019169708 A1 WO 2019169708A1
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WIPO (PCT)
Prior art keywords
laser cutting
copper foil
wireless charging
cut
charging coil
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PCT/CN2018/084481
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English (en)
French (fr)
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肖聪雨
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东莞领益精密制造科技有限公司
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Publication of WO2019169708A1 publication Critical patent/WO2019169708A1/zh

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    • 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
    • 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
    • H01F41/12—Insulating of windings
    • H01F41/122—Insulating between turns or between winding layers
    • 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
    • H01F41/12—Insulating of windings
    • H01F41/127—Encapsulating or impregnating

Definitions

  • the present invention relates to the field of wireless charging coil manufacturing, and more particularly to a wireless charging coil manufacturing method combining a stamping process and a laser cutting process.
  • 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.
  • CN104465067A 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.
  • 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.
  • 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.
  • a wireless charging coil manufacturing process is provided as follows;
  • the inner hole and the outer shape of the wireless charging coil are processed by stamping on the copper foil;
  • 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.
  • 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 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.
  • the present invention prefers to perform preliminary laser cutting and subsequent laser cutting, respectively, using different laser stations.
  • the processing of the inner hole and the outer shape of the wireless charging coil is performed by a stamping process, but the processing of the arc-shaped copper wire is performed by a laser cutting method, because the processing of the inner hole and the outer shape portion is relatively complicated. It can be operated with a relatively low-cost stamping process, but the processing accuracy of the arc-shaped copper wire is very high, and a relatively accurate laser cutting process can be used to obtain better product quality.
  • 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.
  • 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.
  • the copper foil prior to the preliminary laser cutting, is rolled copper, pulled through a puller, and continuously conveyed for preliminary laser cutting.
  • the first station is configured to perform preliminary laser cutting of the copper foil
  • 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.
  • 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.
  • 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.
  • the scrap is removed after subsequent laser cutting of the copper foil.
  • the waste generated by subsequent laser cutting is excluded.
  • 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.
  • the plurality of helical coils that are laser cut are stacked in series horizontally or vertically.
  • the charging coils are officially used, they are often stacked in series horizontally or vertically, thereby achieving higher charging efficiency.
  • the lamination operation is performed by a third station, and after subsequent laser cutting, the film is removed.
  • the copper foil is subjected to a stamping operation by a fourth station, and the inner hole and the outer shape of the wireless charging coil are processed by stamping.
  • FIG. 1 is a schematic flow chart of a manufacturing process of a wireless charging coil according to an embodiment of the present invention
  • FIG. 2 is a schematic diagram showing the effect of a manufacturing process of a wireless charging coil according to an embodiment of the present invention
  • FIG. 3 is a schematic diagram of a production line of a manufacturing process of a wireless charging coil according to an embodiment of the present invention
  • FIG. 4 is a schematic flow chart of a manufacturing process of a wireless charging coil according to still another embodiment of the present invention.
  • FIG. 1 to 4 schematically show the present invention.
  • the wireless charging coil manufacturing process of an embodiment shown in FIG. 1 includes the following steps;
  • Step S1 processing the inner hole and shape of the wireless charging coil by using a stamping process on the copper foil
  • Step S2 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 S3 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 S4 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.
  • the copper foil is stepwise cut.
  • 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.
  • 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 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.
  • the present invention is more inclined to perform preliminary laser cutting and subsequent laser cutting using different laser stations.
  • the processing of the inner hole and the outer shape of the wireless charging coil is performed by a stamping process, but the processing of the arc-shaped copper wire is performed by a laser cutting method, because the processing of the inner hole and the outer shape portion is relatively complicated. It can be operated with a relatively low-cost stamping process, but the processing accuracy of the arc-shaped copper wire is very high, and a relatively accurate laser cutting process can be used to obtain better product quality.
  • 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. .
  • 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.
  • 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.
  • the first station 102 is arranged to perform preliminary laser cutting of the copper foil
  • the second station 104 is arranged 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-described rolled copper material 100 is pulled out by the puller 101, so that automatic production can be realized.
  • step S21 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.
  • 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.
  • the scrap is removed after the subsequent laser cutting of the copper foil.
  • the waste generated by subsequent laser cutting is excluded.
  • the method further includes the step S5: 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.
  • the plurality of helical coils formed by laser cutting may be stacked in series horizontally or vertically.
  • the charging coils are officially used, they are often stacked in series horizontally or vertically, thereby achieving higher charging efficiency.
  • the filming operation is performed by the third station 103, and after the subsequent laser cutting, the film is removed.
  • the copper foil is punched by the fourth station 107, and the inner hole and the outer shape of the wireless charging coil are preliminarily machined by pressing.
  • a layer of packaging film can be covered on the final official wireless charging coil product, which facilitates transportation and subsequent pick-and-place installation.
  • the wireless charging coil specification parameters that can be realized by the manufacturing process of the present invention are as follows:

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Abstract

一种无线充电线圈制造工艺，如下；在铜箔利用冲压加工出无线充电线圈的内孔和外形（S1）；将铜箔进行初步镭射切割，初步镭射切割仅对铜箔的部分区域进行切割，在铜箔上切割出弧状铜线（S2）；将铜箔进行后续镭射切割，后续镭射切割对铜箔的又一部分区域进行切割，并在铜箔上切割出弧状铜线（S3）；初步镭射切割出的弧状铜线与后续镭射切割出的弧状铜线形成连续性的螺旋状线圈（S4）。其有益效果是，初步镭射切割出来的弧状铜线基本与铜箔本身可以保持在一个平面上，即不会发生严重的垂落现象，这样才可以方便进行旋转、输送或者覆膜等操作。然后进行后续镭射切割，后续镭射切割时则对铜箔的另一部分区域进行切割，并让初步镭射切割出的弧状铜线与后续镭射切割出的弧状铜线形成连续性的螺旋状线圈，从而实现无线充电线圈的制造。

Description

无线充电线圈制造工艺 技术领域
本发明涉及无线充电线圈制造领域，尤其涉及一种结合冲压工艺和镭射切割工艺的无线充电线圈制造方法。
背景技术
现有的线圈加工采用铜线缠绕方式，尺寸精度差，效率低，无法满足无线充电线圈的技术要求。
当前也有一些新的无线充电线圈制造方法，例如公开号为：CN104465067A的中国发明专利，就公开了一种一种无线充电线圈的制作方法，包括以下步骤：1)准备塑胶件；制备可激光活化的涂料；2)在所述塑胶件正面和背面的待处理区域均喷涂一层所述可激光活化的涂料；3)使用激光在塑胶件正面镭射出螺旋线圈槽和馈点槽，在内部端点和第二馈点槽上均设置通孔；且使用激光在塑胶件背面上镭射出图案槽；4)清洗步骤3)处理后的塑胶件；5)对所述塑胶件表面的槽内依次进行化学镀铜、电学镀铜处理。其方法预先设置螺旋线圈槽和馈点槽，然后再使用化学镀铜或者电学镀铜的方式在螺旋线圈槽和馈点槽形成铜层，最终形成无线充电线圈。但是这种方式仍有不足之处，制造方法非常的复杂，化学镀铜或者电学镀铜操作复杂，而且容易产生污染。同时螺旋线圈槽和馈点槽必然要有一定的壁厚，从而导致充电线圈之间的间隙较大，最后的产品充电效率不高。
发明内容
本发明的目的是提供无线充电线圈制造工艺，可以解决上述现有技术问题中的一个或多个。
根据本发明一个方面，提供了无线充电线圈制造工艺，如下；
在铜箔利用冲压加工出无线充电线圈的内孔和外形；
将铜箔进行初步镭射切割，初步镭射切割仅对铜箔的部分区域进行切割，在铜箔上切割出弧状铜线；
将铜箔进行后续镭射切割，后续镭射切割对铜箔的又一部分区域进行切割，并在铜箔上切割出弧状铜线；
初步镭射切割出的弧状铜线与后续镭射切割出的弧状铜线形成连续性的螺旋状线圈。
其有益效果是，直接对片状的铜箔进行镭射切割，可以采用红外光或者紫外光进行切割，在切割的过程当中，对铜箔进行分步切割，初步镭射切割时，仅对铜箔的部分区域进行切割，初步镭射切割的程度，尽量以初步镭射切割出来的弧状铜线在铜箔悬空的状态下，初步镭射切割出来的弧状铜线基本与铜箔本身可以保持在一个平面上，即不会发生严重的垂落现象，这样才可以方便进行旋转、输送或者覆膜等操作。然后进行后续镭射切割，后续镭射切割时则对铜箔的另一部分区域进行切割，并让初步镭射切割出的弧状铜线与后续镭射切割出的弧状铜线形成连续性的螺旋状线圈，从而实现无线充电线圈的制造。
由于本发明是直接采用镭射切割的方式进行生产，所以切割的精度可以非常的高，可以达到0.05mm的精度。
初步镭射切割和后续镭射切割可以采用同一个镭射工站，在初步镭射切割后，再旋转铜箔后，对铜箔的另一区域进行后续镭射切割。或者直接让镭射工站进行旋转角度，对铜箔的另一区域进行后续镭射切割。
通常而言，本发明更倾向于采用不同的镭射工站分别进行初步镭射切割和后续镭射切割。
本发明当中，将无线充电线圈的内孔和外形的加工利用冲压工艺进行操作，但是弧状铜线的加工则采用镭射切割的方式，因为相对而言，内孔和外形部的加工并不复杂，可以采用成本相对较低的冲压工艺进行操作，但是弧状铜线的加工相对精确度要求非常高，采用相对精确的镭射切割工艺，可以得到更好的产品质量。
在一些实施方式中，将待切割的铜箔分成四个象限区域，初步镭射切割时仅对第一象限和第三象限进行切割，后续镭射切割时再对第二象限和第四象限进行切割。通过错位切割的方式，保证初步镭射切割的时候，只有第一象限和第三象限的铜箔被镭射切割产生了初步镭射切割出的弧状铜线，这种弧状铜线只有四分之一个圆大小，所以基本不会产生垂落现象，可以保证初步镭射切割出的弧状铜线与铜箔仍然基本处于同一平面上。如果是直接分割成两个半圆区域，初步镭射切割时直接切割一个半圆的区域，则可能产生一定的垂落现象。
当然也可以将整个圆分成三等分区域，从而进行一次初步镭射切 割和两次后续镭射切割，通过三次切割来完成整个充电线圈的切割。或者直接进行八等分，将8个等分区域分别编号1、2、3、4、5、6、7、8。初步镭射切割时，对1、3、5、7四个区域进行初步镭射切割，后续镭射切割的时候，对2、4、6、8四个区域进行后续镭射切割。相对而言，等分的份数越多，可以保证初步镭射切割出来的弧状铜线更不易发生垂落现象。
在一些实施方式中，在初步镭射切割之前，铜箔为卷状铜材，通过拉料器拉出，连续性的输送进行初步镭射切割。
在一些实施方式中，设置第一工站对铜箔进行初步镭射切割，设置第二工站对铜箔进行后续镭射切割。通过两个工站来对铜箔进行切割，从而可以实现连续性的加工，结合前述的卷状铜材通过拉料器拉出，从而可以实现自动化生产。
在一些实施方式中，为了更好的防止初步镭射切割出来的弧状铜线发生垂落，可以在初步镭射切割和后续镭射切割之间，对初步镭射切割后的铜箔进行覆膜。如果不进行覆膜，在后续镭射切割完全结束的一瞬间，整个切割出来的线圈实质是完全悬空了，没有旁边的支撑力，特别容易发生垂落现象，但是通过在初步镭射切割和后续镭射切割之间，对铜箔进行覆一层膜后，可以保证整个铜箔可以被覆膜支撑住，即初步镭射切割完成后，只有部分区域被初步镭射切割出来的弧状铜线是悬空的，但是覆膜后，初步镭射切割出来的弧状铜线是被覆膜支撑的，后续镭射切割时会将又一部分区域进行切割，并将相应位置的覆膜也切割掉。后续镭射切割出的弧状铜线此时是悬空状态的。即通过覆膜后可以保证初步镭射切割出来的弧状铜线和后续镭射切割出的弧状铜线是仅仅择一悬空的，并不会全部悬空，从而保证整个线圈不会发生严重的垂落现象。
在一些实施方式中，在铜箔后续镭射切割后排除废料。将后续镭射切割产生的废料进行排除。
在一些实施方式中，对切割出的螺旋状线圈进行烤绝缘漆操作，利用绝缘漆填充线圈之间的间隙。由于镭射切割的工艺可以做到非常精确，线圈的铜线之间的间隙可以达到0.05mm的精度，所以容易产生导通短路的情况，通过对螺旋状线圈进行烤绝缘漆操作，可以防止短路的发生，保证产品的正常使用。
在一些实施方式中，将镭射切割成型的多个螺旋状线圈呈水平状串联在一起或者垂直方向层叠在一起。充电线圈在正式使用的时候， 常常会水平状串联在一起或者垂直方向层叠在一起，从而实现更高的充电效率。
在一些实施方式中，通过第三工站进行覆膜操作，在后续镭射切割后，再去除覆膜。
在一些实施方式中，通过第四工站对铜箔进行冲压操作，利用冲压加工出无线充电线圈的内孔和外形。
附图说明
图1为本发明一实施方式的无线充电线圈制造工艺的流程示意图；
图2为本发明一实施方式的无线充电线圈制造工艺的效果示意图；
图3为本发明一实施方式的无线充电线圈制造工艺的产线示意图；
图4为本发明又一实施方式的无线充电线圈制造工艺的流程示意图。
具体实施方式
下面结合附图对本发明作进一步详细的说明。
图1至图4示意性地显示了本发明。如图1所示一种实施方式的无线充电线圈制造工艺，包括如下步骤；
步骤S1：在铜箔利用冲压加工出无线充电线圈的内孔和外形
步骤S2：将铜箔进行初步镭射切割，初步镭射切割仅对铜箔的部分区域进行切割，在铜箔上切割出弧状铜线；
步骤S3：将铜箔进行后续镭射切割，后续镭射切割对铜箔的又一部分区域进行切割，并在铜箔上切割出弧状铜线；
步骤S4：初步镭射切割出的弧状铜线与后续镭射切割出的弧状铜线形成连续性的螺旋状线圈。
直接对片状的铜箔进行镭射切割，可以采用红外光或者紫外光进行切割，在切割的过程当中，对铜箔进行分步切割，初步镭射切割时，仅对铜箔的部分区域进行切割，初步镭射切割的程度，尽量以初步镭射切割出来的弧状铜线在铜箔悬空的状态下，初步镭射切割出来的弧状铜线基本与铜箔本身可以保持在一个平面上，即不会发生严重的垂落现象，这样才可以方便进行旋转、输送或者覆膜等操作。然后进行 后续镭射切割，后续镭射切割时则对铜箔的另一部分区域进行切割，并让初步镭射切割出的弧状铜线与后续镭射切割出的弧状铜线形成连续性的螺旋状线圈，从而实现无线充电线圈的制造。
由于本发明是直接采用镭射切割的方式进行生产，所以切割的精度可以非常的高，可以达到0.05mm的精度。
初步镭射切割和后续镭射切割可以采用同一个镭射工站，在初步镭射切割后，再旋转铜箔后，对铜箔的另一区域进行后续镭射切割。或者直接让镭射工站进行旋转角度，对铜箔的另一区域进行后续镭射切割。
通常而言，如图3所示，本发明更倾向于采用不同的镭射工站分别进行初步镭射切割和后续镭射切割。
本发明当中，将无线充电线圈的内孔和外形的加工利用冲压工艺进行操作，但是弧状铜线的加工则采用镭射切割的方式，因为相对而言，内孔和外形部的加工并不复杂，可以采用成本相对较低的冲压工艺进行操作，但是弧状铜线的加工相对精确度要求非常高，采用相对精确的镭射切割工艺，可以得到更好的产品质量。
如图2所示，可以将待切割的铜箔分成四个象限区域，初步镭射切割时仅对第一象限和第三象限进行切割，后续镭射切割时再对第二象限和第四象限进行切割。通过错位切割的方式，保证初步镭射切割的时候，只有第一象限和第三象限的铜箔被镭射切割产生了初步镭射切割出的弧状铜线，这种弧状铜线只有四分之一个圆大小，所以基本不会产生垂落现象，可以保证初步镭射切割出的弧状铜线与铜箔仍然基本处于同一平面上。如果是直接分割成两个半圆区域，初步镭射切割时直接切割一个半圆的区域，则可能产生一定的垂落现象。
当然也可以将整个圆分成三等分区域，从而进行一次初步镭射切割和两次后续镭射切割，通过三次切割来完成整个充电线圈的切割。或者直接进行八等分，将8个等分区域分别编号1、2、3、4、5、6、7、8。初步镭射切割时，对1、3、5、7四个区域进行初步镭射切割，后续镭射切割的时候，对2、4、6、8四个区域进行后续镭射切割。相对而言，等分的份数越多，可以保证初步镭射切割出来的弧状铜线更不易发生垂落现象。
如图3、4所示，还包括步骤S0：在初步镭射切割之前，铜箔为卷状铜材，通过拉料器101拉出，连续性的输送进行初步镭射切割。
如图3所示，设置第一工站102对铜箔进行初步镭射切割，设置 第二工站104对铜箔进行后续镭射切割。通过两个工站来对铜箔进行切割，从而可以实现连续性的加工，结合前述的卷状铜材100通过拉料器101拉出，从而可以实现自动化生产。
通常，如图3、4所示，为了更好的防止初步镭射切割出来的弧状铜线发生垂落，可以进行步骤S21：在初步镭射切割和后续镭射切割之间，对初步镭射切割后的铜箔进行覆膜。如果不进行覆膜，在后续镭射切割完全结束的一瞬间，整个切割出来的线圈实质是完全悬空了，没有旁边的支撑力，特别容易发生垂落现象，但是通过在初步镭射切割和后续镭射切割之间，对铜箔进行覆一层膜后，可以保证整个铜箔可以被覆膜支撑住，即初步镭射切割完成后，只有部分区域被初步镭射切割出来的弧状铜线是悬空的，但是覆膜后，初步镭射切割出来的弧状铜线是被覆膜支撑的，后续镭射切割时会将又一部分区域进行切割，并将相应位置的覆膜也切割掉。后续镭射切割出的弧状铜线此时是悬空状态的。即通过覆膜后可以保证初步镭射切割出来的弧状铜线和后续镭射切割出的弧状铜线是仅仅择一悬空的，并不会全部悬空，从而保证整个线圈不会发生严重的垂落现象。
同时，在铜箔后续镭射切割后排除废料。将后续镭射切割产生的废料进行排除。
如图4所示，还包括步骤S5：对切割出的螺旋状线圈进行烤绝缘漆操作，利用绝缘漆填充线圈之间的间隙。由于镭射切割的工艺可以做到非常精确，线圈的铜线之间的间隙可以达到0.05mm的精度，所以容易产生导通短路的情况，通过对螺旋状线圈进行烤绝缘漆操作，可以防止短路的发生，保证产品的正常使用。烤绝缘漆操作可以直接在图3所示的流水线上设置烤漆工站105进行操作，也可以进行是进行单独的后续操作，单独进行烤绝缘漆操作。
最终形成产品106时，可以将镭射切割成型的多个螺旋状线圈呈水平状串联在一起或者垂直方向层叠在一起。充电线圈在正式使用的时候，常常会水平状串联在一起或者垂直方向层叠在一起，从而实现更高的充电效率。
如图3所示，通过第三工站103进行覆膜操作，在后续镭射切割后，再去除覆膜。通过第四工站107对铜箔进行冲压操作，利用冲压预先加工出无线充电线圈的内孔和外形。
同时可以在最终的正式的无线充电线圈产品上覆盖一层包装膜，从而方便运输和后续的取放安装等操作。
利用本发明的制造工艺可以实现的无线充电线圈规格参数如下：
Figure PCTCN2018084481-appb-000001
以上的仅是本发明的一些实施方式。对于本领域的普通技术人员来说，在不脱离本发明创造构思的前提下，还可以做出若干变形和改进，这些都属于本发明的保护范围。

Claims (10)

  1. 无线充电线圈制造工艺，其特征在于；
    在铜箔利用冲压加工出无线充电线圈的内孔和外形；
    将铜箔进行初步镭射切割，初步镭射切割仅对铜箔的部分区域进行切割，在铜箔上切割出弧状铜线；
    将铜箔进行后续镭射切割，后续镭射切割对铜箔的又一部分区域进行切割，并在铜箔上切割出弧状铜线；
    初步镭射切割出的弧状铜线与后续镭射切割出的弧状铜线形成连续性的螺旋状线圈。
  2. 根据权利要求1所述的无线充电线圈制造工艺，其特征在于，将待切割的铜箔分成四个象限区域，初步镭射切割时仅对第一象限和第三象限进行切割，后续镭射切割时再对第二象限和第四象限进行切割。
  3. 根据权利要求1所述的无线充电线圈制造工艺，其特征在于，设置第一工站对铜箔进行初步镭射切割，设置第二工站对铜箔进行后续镭射切割。
  4. 根据权利要求1所述的无线充电线圈制造工艺，其特征在于，在初步镭射切割和后续镭射切割之间，对初步镭射切割后的铜箔进行覆膜。
  5. 根据权利要求1所述的无线充电线圈制造工艺，其特征在于，还包括如下步骤：
    铜箔为卷状铜材，通过拉料器拉出，连续性的输送进行初步镭射切割。
  6. 根据权利要求1所述的无线充电线圈制造工艺，其特征在于，在铜箔后续镭射切割后排除废料。
  7. 根据权利要求1所述的无线充电线圈制造工艺，其特征在于，对切割出的螺旋状线圈进行烤绝缘漆操作，利用绝缘漆填充线圈之间 的间隙。
  8. 根据权利要求1所述的无线充电线圈制造工艺，其特征在于，将镭射切割成型的多个螺旋状线圈呈水平状串联在一起或者垂直方向层叠在一起。
  9. 根据权利要求4所述的无线充电线圈制造工艺，其特征在于，通过第三工站进行覆膜操作，在后续镭射切割后，再去除覆膜。
  10. 根据权利要求1所述的无线充电线圈制造工艺，其特征在于，通过第四工站对铜箔进行冲压操作，利用冲压加工出无线充电线圈的内孔和外形。
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