WO2019169709A1

WO2019169709A1 - Wireless charging coil stamping manufacturing process

Info

Publication number: WO2019169709A1
Application number: PCT/CN2018/084482
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: CN108511182A; CN108511182B

Abstract

Disclosed by the present invention is a wireless charging coil stamping manufacturing process, comprising the following steps: performing preliminary stamping on a copper foil, wherein only a partial area of the copper foil is stamped in the preliminary stamping, and a curved copper wire is stamped on the copper coil; performing subsequent stamping on the copper foil, wherein another partial area of the copper foil is stamped in the subsequent stamping, and a curved copper wire is stamped on the copper coil; after the preliminary stamping and the subsequent stamping, preserving a connection part between the partial area and the another partial area, wherein the connection part is used for connecting the curved copper wire from the preliminary stamping, the copper wire from the subsequent stamping, and the copper foil body together; covering a film on the copper foil; cutting off the connection part such that the curved copper wire from the preliminary stamping and the curved copper wire from the subsequent stamping form a continuous spiral coil. The advantageous effects of the process are that the continuous and automated production of a wireless charging coil may be achieved, and the accuracy is high.

Description

Wireless charging coil stamping manufacturing process

Technical field

The present invention relates to the field of wireless charging coil manufacturing, and more particularly to a wireless charging coil stamping 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 laser-activated paint on the front and back areas of the plastic part; 3) using a laser to laser out the spiral coil groove and feed point groove on the front side of the plastic part, at the inner end point and the second feed A through hole is arranged in the dot slot; and a laser is used to laser the pattern groove on the back surface of the plastic part; 4) the cleaning step 3) the plastic part after the treatment; 5) the electroless copper plating and the electric plating are sequentially performed on the surface of the plastic part. Copper 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 stamping manufacturing process that addresses one or more of the above prior art problems.

According to one aspect of the invention, a wireless charging coil stamping manufacturing process is provided, wherein:

The copper foil is subjected to preliminary stamping, and the preliminary stamping only punches a part of the copper foil, and punches the curved copper wire on the copper foil;

Subsequent stamping of the copper foil, subsequent stamping of a further portion of the copper foil, and stamping the curved copper wire on the copper foil;

After the preliminary stamping and the subsequent stamping, a connecting portion is left between the partial region and a part of the region, and the connecting portion is used for connecting the initially punched arc-shaped copper wire, the subsequently punched copper wire and the copper foil body;

Covering the copper foil with a film;

The connecting portion is cut off such that the initially punched arc-shaped copper wire forms a continuous spiral coil with the subsequently punched curved copper wire.

The beneficial effect is that the sheet-shaped copper foil is directly stamped and formed, and the copper foil is stepwise stamped during the stamping process. When the preliminary stamping is performed, only a part of the copper foil is punched, and the degree of preliminary stamping is as far as possible. The arc-shaped copper wire which is initially punched out is in a state in which the copper foil is suspended, and the arc-shaped copper wire which is initially punched out can be kept on a plane substantially with the copper foil itself, that is, no serious drooping phenomenon occurs, so that the rotation can be easily performed. , transport or filming operations. Subsequent stamping is then carried out, and another portion of the copper foil is stamped during subsequent stamping.

A region is reserved between the preliminary stamping and the subsequent stamping, that is, a joint is left between the partial region and a portion of the region, and the joint portion is used for the initially punched arc-shaped copper wire, the subsequently punched copper wire, and copper. The foil bodies are connected together, which prevents the arc-shaped copper wires from prolapsed in the state in which the copper foil is suspended. If there is no connection portion to connect, the arc-shaped copper wires will cause serious prolapse, resulting in deformation of the product.

After the final covering film is applied, the connecting portion is punched and the connecting portion is cut. At this time, since the film is already coated, the curved copper wire is supported by the film, and no prolapse phenomenon occurs. After the connecting portion is cut off, the initially drawn arc-shaped copper wire can be connected with the subsequently punched arc-shaped copper wire to form a continuous spiral coil, thereby realizing the manufacture of the wireless charging coil.

The film here generally adopts a low mucous membrane, that is, the film can be adhered to the copper foil, but the adhesion is very small, and the separation can be carried out very conveniently.

Since the invention is directly produced by means of stamping, the precision of the stamping can be very high, and the precision of 0.05 mm can be achieved.

The initial stamping and subsequent stamping can be carried out by the same stamping station. After the preliminary stamping, after rotating the copper foil, another area of the copper foil is subsequently stamped. Or directly let the stamping station rotate the angle and carry out subsequent stamping on another area of the copper foil.

In general, the present invention is more prone to separate stamping and subsequent stamping using different stamping stations.

In some embodiments, the copper foil to be stamped is divided into four quadrant regions, and only the first and third quadrants are stamped during preliminary stamping, and the second and fourth quadrants are stamped during subsequent stamping. The beneficial effect is that, by means of misalignment stamping, when the preliminary stamping is ensured, only the first and third quadrants of the copper foil are stamped to produce a preliminary stamped arc-shaped copper wire, and the arc-shaped copper wire is only one quarter. The size of the circle is so that there is no drooping phenomenon, and it can be ensured that the arc-shaped copper wire which is initially punched out and the copper foil are still substantially in the same plane. If it is directly divided into two semi-circular areas, a semi-circular area is directly punched during the initial punching, 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 one preliminary punching and two subsequent punching, and punching the entire charging coil by three punching. Or directly octave, and number 8 aliquots are numbered 1, 2, 3, 4, 5, 6, 7, and 8. During the initial stamping, the first, third, fifth, and seventh regions are subjected to preliminary stamping, and in the subsequent stamping, the second, second, fourth, and eighth regions are subjected to subsequent stamping. Relatively speaking, the more parts are equally divided, the smaller the arc-shaped copper wire that is initially punched out can be prevented from falling down.

In some embodiments, the film is provided with a through hole corresponding to the position of the connecting portion, and the range of the through hole is greater than or equal to the range of the connecting portion. The beneficial effect is that, when the punching operation is performed, a hard support is needed at the bottom of the copper foil, and after the through hole is provided, the hard support can directly contact the bottom of the copper foil through the through hole, thereby forming A good support, so as to facilitate the smooth operation of the punching and cutting joint, but if the through hole is not provided on the film, the film is completely covered on the copper foil, when the joint is cut off, the joint portion The bottom is covered with a film. Since the film is usually made of plastic material, it is very soft compared to the copper foil, and it has a certain elasticity, so it cannot be formed at the bottom of the joint. The hard support is prone to errors when the joint is cut off, and it is impossible to connect the precise cut, which ultimately affects the quality of the product.

In some embodiments, the method further includes the following steps:

The copper foil is a rolled copper material which is pulled out by a puller and is continuously drawn for continuous conveyance.

In some embodiments, the first station is configured to perform preliminary stamping of the copper foil, and the second station is configured to perform subsequent stamping of the copper foil. The beneficial effect is that the copper foil is punched by two stations, so that continuous processing can be realized, and the above-mentioned rolled copper material is pulled out through the puller, thereby realizing automatic production. At the same time, the film coating operation can also be carried out by using a roll-shaped film material to be bonded with the copper foil to perform a joint film coating operation, and the roll film material can also be used to directly tear the film material after the completion of the post-process. Open to achieve waste disposal operations.

In some embodiments, the scrap is removed after the copper foil has cut the joint.

In some embodiments, the formed spiral coil is subjected to a baking varnish operation, and the gap between the coils is filled with an insulating varnish. The beneficial effect is that since the stamping 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 spiral coil is subjected to the baking varnish operation. It can prevent the occurrence of short circuit and ensure the normal use of the product.

In some embodiments, the plurality of shaped helical coils are stacked in series horizontally or vertically together. 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 filming operation is performed by the third station, and the fourth station is set to perform the cutting connection operation, and after the connection portion is removed, the film is removed.

In some embodiments, the inner hole and profile of the wireless charging coil are continuously stamped in the copper foil. The result is a formal wireless charging coil product.

DRAWINGS

1 is a flow chart showing a stamping manufacturing process of a wireless charging coil according to an embodiment of the present invention.

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

FIG. 3 is a schematic structural view of a product after stamping of a wireless charging coil in a stamping manufacturing process according to an embodiment of the present invention.

Figure 4 is an enlarged schematic view of a portion A of Figure 3.

FIG. 5 is a schematic view showing a production line of a stamping manufacturing process of a wireless charging coil according to an embodiment of the present invention.

FIG. 6 is a schematic flow chart of a stamping manufacturing process of a wireless charging coil according to an embodiment of the present invention.

FIG. 7 is a schematic view showing a film coating operation of a wireless charging coil stamping manufacturing process according to an embodiment of the present invention.

Detailed ways

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

1 to 7 schematically show the present invention.

The wireless charging coil stamping manufacturing process of an embodiment shown in FIG. 1 includes the following steps;

Step S1: preliminary pressing the copper foil, the preliminary stamping only punches a part of the copper foil, and punches the curved copper wire on the copper foil;

Step S2: performing subsequent stamping on the copper foil, and subsequently stamping a further portion of the copper foil, and punching the curved copper wire on the copper foil;

Step S3: after the preliminary stamping and the subsequent stamping, a connecting portion is left between the partial region and a part of the region, and the connecting portion is used for connecting the initially punched arc-shaped copper wire, the subsequently punched copper wire and the copper foil body together;

Step S4: covering the copper foil with a coating film;

Step S5: cutting the connecting portion, so that the initially punched arc-shaped copper wire forms a continuous spiral coil with the subsequently punched curved copper wire.

As shown in FIG. 2, the present invention directly presses a copper foil in a stamping process, and performs stepwise stamping on the copper foil during the stamping process. When the preliminary stamping is performed, only a part of the copper foil is stamped, and the preliminary stamping is performed. To the extent that the arc-shaped copper wire which is initially punched out is in a state in which the copper foil is suspended, the arc-shaped copper wire which is initially punched out can be kept on a plane substantially with the copper foil itself, that is, no serious drooping phenomenon occurs. It can be easily rotated, transported or laminated. Subsequent stamping is then carried out, and another portion of the copper foil is stamped during subsequent stamping.

As shown in Figures 2, 3 and 4, a portion of the area is reserved between the preliminary stamping and the subsequent stamping, i.e., a portion 201 is left between the partial region and a further portion of the region, and the connecting portion 201 is used for preliminary punching out. The arc-shaped copper wire 202, the subsequently stamped copper wire 203 and the copper foil body 204 are connected together, so as to prevent the arc-shaped copper wire from prolapsed in a state in which the copper foil is suspended, and if there is no connection portion for connection, the curved copper wire will be Serious prolapse will occur, causing deformation of the product.

The initial stamping and subsequent stamping can be carried out by the same stamping station. After the preliminary stamping, the copper foil is rotated and the other part of the copper foil is subsequently stamped. Or directly let the stamping station rotate the angle and carry out subsequent stamping on another part of the copper foil.

In general, as shown in Figure 5, the present invention is more prone to preliminary stamping and subsequent stamping using different stamping stations.

As shown in FIG. 2, the copper foil to be stamped can be divided into four quadrant regions, and only the first quadrant and the third quadrant are punched during the preliminary stamping, and the second quadrant and the fourth quadrant are stamped after the subsequent stamping, which is equivalent. In the first quadrant and the third quadrant as partial regions, the second quadrant and the fourth quadrant problem are originally another partial region. The beneficial effect is that, by means of misalignment stamping, when the preliminary stamping is ensured, only the first and third quadrants of the copper foil are stamped to produce a preliminary stamped arc-shaped copper wire, and the arc-shaped copper wire is only one quarter. The size of the circle is so that there is no drooping phenomenon, and it can be ensured that the arc-shaped copper wire which is initially punched out and the copper foil are still substantially in the same plane. If it is directly divided into two semi-circular areas, a semi-circular area is directly punched during the initial punching, which may cause a certain drooping phenomenon.

As shown in Fig. 6, the present invention further includes a step S0: before the preliminary pressing, the copper foil is a rolled copper material 100, which is pulled out by the puller 101, and the preliminary conveyance is performed by continuous conveyance.

As shown in FIG. 5, the first station 102 is provided to perform preliminary stamping on the copper foil, and the second station 103 is provided to perform subsequent stamping on the copper foil. The copper foil is punched 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.

As shown in FIG. 7, the film 205 is provided with a through hole 206 corresponding to the position of the connecting portion 201, and the range of the through hole 206 is greater than or equal to the range of the connecting portion 201. Since the punching operation requires a hard support at the bottom of the copper foil, after the through hole 206 is provided, the hard support can directly contact the bottom of the copper foil through the through hole 206, thereby forming a good one. Supporting, thereby facilitating the smooth operation of the punching and cutting connection portion 201, but if the through hole is not provided on the film 205, the film 205 is completely covered on the copper foil, when the cutting connection portion 201 is performed, the connecting portion The bottom of 201 is covered with the film 205. Since the film 205 is usually made of a plastic material, it is very soft relative to the copper foil and has a certain elasticity, so at the bottom of the connecting portion 201 A stable hard support that cannot be formed is prone to error when the connecting portion 201 is cut off, and it is impossible to connect an accurate cut, thereby ultimately affecting product quality.

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

As shown in FIG. 6, the present invention may further include a step S6 of performing a baking varnish operation on the punched spiral coil, and filling the gap between the coils with the insulating varnish. Since the laser stamping 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 performed by directly setting the paint station 106 on the line shown in FIG. 5, or performing a separate subsequent operation to separately perform the baking varnish operation.

When the product 107 is finally formed, the plurality of helical coils formed by laser stamping 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. 5, the filming operation is performed by the third station 104, and the fourth station 105 is installed to perform the cutting connection operation, and after the connection portion is cut, the film is removed.

At the same time, it is also possible to continue stamping and processing the inner hole and shape of the wireless charging coil after the subsequent pressing 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 stamping manufacturing process, characterized in that;

The copper foil is subjected to preliminary stamping, and the preliminary stamping only punches a part of the copper foil, and punches the curved copper wire on the copper foil;

Subsequent stamping of the copper foil, subsequent stamping of a further portion of the copper foil, and stamping the curved copper wire on the copper foil;

After the preliminary stamping and the subsequent stamping, a connecting portion is left between the partial region and a part of the region, and the connecting portion is used for connecting the initially punched arc-shaped copper wire, the subsequently punched copper wire and the copper foil body;

Covering the copper foil with a film;

The connecting portion is cut off such that the initially punched arc-shaped copper wire forms a continuous spiral coil with the subsequently punched curved copper wire.
A stamping manufacturing process for a wireless charging coil according to claim 1, wherein the copper foil to be stamped is divided into four quadrant regions, and only the first quadrant and the third quadrant are punched during preliminary stamping, and the second stamping is performed after the stamping. The quadrant and the fourth quadrant are stamped.
The wireless charging coil stamping manufacturing process according to claim 1, characterized in that the first station is provided for preliminary stamping of the copper foil, and the second station is provided for subsequent stamping of the copper foil.
The wireless charging coil stamping manufacturing process according to claim 1, wherein the film is provided with a through hole corresponding to a position of the connecting portion, and the range of the through hole is greater than or equal to a range of the connecting portion.
The wireless charging coil stamping 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 is continuously drawn for continuous conveyance.
The wireless charging coil stamping manufacturing process according to claim 1, wherein the scrap is removed after the copper foil cuts off the joint.
The wireless charging coil stamping manufacturing process according to claim 1, wherein the formed 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 stamping manufacturing process according to claim 1, wherein the plurality of formed spiral coils are horizontally connected in series or vertically stacked.
The wireless charging coil stamping manufacturing process according to claim 4, wherein the filming operation is performed by the third station, and the fourth station is provided to perform the cutting connection operation, and after the connection portion is removed, the film is removed.
The wireless charging coil stamping manufacturing process according to claim 1, wherein the inner hole and the outer shape of the wireless charging coil are continuously stamped in the copper foil.