WO2019218392A1 - 一种双线圈的充电线圈及其制造方法 - Google Patents

一种双线圈的充电线圈及其制造方法 Download PDF

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Publication number
WO2019218392A1
WO2019218392A1 PCT/CN2018/088419 CN2018088419W WO2019218392A1 WO 2019218392 A1 WO2019218392 A1 WO 2019218392A1 CN 2018088419 W CN2018088419 W CN 2018088419W WO 2019218392 A1 WO2019218392 A1 WO 2019218392A1
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Prior art keywords
coil
charging
manufacturing
inner end
spacing
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PCT/CN2018/088419
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English (en)
French (fr)
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梁平平
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东莞领益精密制造科技有限公司
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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
    • 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
    • H01F27/2823—Wires
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F38/00—Adaptations of transformers or inductances for specific applications or functions
    • H01F38/14—Inductive couplings
    • 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
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02J—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

Definitions

  • the invention relates to the field of charging coil manufacturing, and in particular to a method for manufacturing a double coil charging coil.
  • the existing coil processing adopts a copper wire winding method, has poor dimensional accuracy, low charging efficiency, and poor heat dissipation effect, 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 coating 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 the feed point groove on the front side of the plastic part, at the inner end point and the second feed point groove A through hole is arranged on the upper side; and a 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) the electroless copper plating and the electrical copper plating are sequentially performed on the surface of the plastic part .
  • 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, the manufacturing method is very complicated, the cost is high, and the electroless copper plating or the electric copper plating operation is complicated, and it is easy to cause 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.
  • the Chinese invention patent application with the publication number CN105934804A also discloses a method for fabricating a wireless charging coil, comprising:
  • the coil combines the first coil and the second coil.
  • This method utilizes an adhesive that has both an adhesive effect and an insulating effect.
  • the adhesive is cured in a normal state, can be used for adhesive fixation, and is fluid in a heated state.
  • the shape can flow so that the coil can be completely wrapped.
  • there is still a shortcoming in this way that is, during the flow of the adhesive, since the adhesive has a certain viscosity, the resistance is very large, and the coil is easily driven, due to the first spacing between the coils and the second The spacing itself is very small. After the mutual fitting, the distance between the first punching coil and the second punching coil is actually very small.
  • a method of manufacturing a double coil charging coil which includes the following steps;
  • Preparing a first coil Preparing a first coil, the first coil having a first spiral trace, a first spacing being left between the windings of the first spiral trace, the first coil comprising a first inner end and a first outer end;
  • the second coil Preparing a second coil, the second coil has a second spiral trace, a second spacing is left between the windings of the second spiral trace, and the second coil includes a second inner end and a second outer end;
  • a first inner end of the first coil is coupled to a second outer end of the second coil.
  • the utility model has the beneficial effects that the invention adopts a method in which the two coils are nested in a nested manner, and the gap between the charging coils of the nested assembled double coils is smaller. Moreover, the first coil and the second coil are located on the same plane, and when applied to the wireless charging coil of the mobile phone, the thickness can be kept to be very small, so that it can be applied to a limited internal space of the mobile phone. Meet the current thinning requirements of mobile phone manufacturing for mobile phones.
  • the first inner end of the first coil and the second outer end of the second coil may be connected by a connecting wire, and the connection may be laser welding or electric resistance welding. It can also be riveted or pressed.
  • the connecting line may be a separate connecting line, or the first inner end of the first coil or the second outer end of the second coil may be intentionally left longer when the first coil or the second coil is prepared, and then The parts that have been long are directly folded and then connected to each other.
  • the method before the assembling operation of the first coil and the second coil, the method further comprises the steps of:
  • An insulating coating is applied to either or both of the first coil and the second coil.
  • the utility model has the beneficial effects that, for the Chinese invention patent application with the publication number of CN105934804A, the technical solution of the invention does not require the adhesive nor the corresponding two laminates, but directly coats the insulating coating. Insulation treatment can be realized, or baking paint can also be used for baking varnish. Therefore, there is no problem that the adhesive is displaced under the hot pressure, and the coil is displaced to cause a short circuit.
  • the method further includes the steps of:
  • An insulating coating is applied to the assembled first coil and second coil.
  • the utility model has the beneficial effects that, for the Chinese invention patent application with the publication number of CN105934804A, the technical solution of the invention does not require the adhesive nor the corresponding two laminates, but directly coats the insulating coating. Insulation treatment can be realized, or baking paint can also be used for baking varnish. Therefore, there is no problem that the adhesive is displaced under the hot pressure, and the coil is displaced to cause a short circuit.
  • the insulation treatment can be performed before or after assembly. Only one of the coils can be processed before assembly, and the first coil and the second coil are naturally insulated from each other after the fitting.
  • the first coil and the second coil utilize any one of stamping, laser cutting, waterjet cutting, and etching using copper foil.
  • the beneficial effect is that the first coil and the second coil can be directly fabricated by using a sheet of copper foil, and the stamping and cutting forming, the laser cutting forming, and the waterjet cutting forming can be selected according to the production process, cost, and environment requirements. Any one of etching and molding.
  • the first coil is adsorbed on the first supporting fixture, and the first supporting fixture is provided with a first adsorption structure corresponding to the position of the first spiral trace;
  • the second coil is adsorbed on the second supporting fixture, and the second supporting fixture is provided with a second adsorption structure corresponding to the position of the second spiral trace;
  • first support fixture and the second support fixture Positioning the first support fixture and the second support fixture symmetrically, and performing a relative pressing operation such that the first coil is positioned within the second pitch of the second coil such that the second coil is positioned at the first of the first coil Within the spacing, the first coil and the second coil are nested in one another and on the same plane.
  • the first coil and the second coil cooperate with each other to adjust the matching gap to a minimum of 0-0.2 mm according to the test requirements.
  • the utility model has the advantages that the first supporting fixture is respectively used to adsorb and fix the first coil, and the second supporting fixture is used to adsorb and fix the second coil, so that the two coils can be fixedly positioned, the position can be very precise, and the two fixtures are passed through
  • the symmetrical arrangement is performed by the relative pressing operation, so that the first coil and the second coil are nested on each other and on the same plane, and the relative position is surely not generated, and the precision is very high.
  • the adsorption structure is a vacuum suction hole or a vacuum suction cup.
  • the beneficial effect is that a good fixing can be achieved by the vacuum suction hole or the vacuum suction cup, and the coil can be prevented from being displaced.
  • any one or both of the first coil and the second coil are coated and insulated. coating.
  • the beneficial effect is that since one side of the first coil is adsorbed on the first supporting jig, the side of the second coil and the side wall of the first spiral trace are bare, and the second coil is also adsorbed on one side. On the second supporting jig, the side of the first coil and the side of the second spiral trace are also bare, so when applying the insulating coating, there are only three faces for the cross section of the spiral trace.
  • the first supporting jig and the second supporting jig are respectively provided with a positioning hole and a positioning pin.
  • the utility model has the beneficial effects that when the first supporting fixture and the second supporting fixture are assembled and assembled, the positioning hole and the positioning pin can be matched to achieve precise positioning and ensure assembly precision.
  • the method further includes the steps of:
  • the assembled first coil and the second coil are subjected to a laminating operation, and a carrier film with a viscous adhesive is applied on either or both sides of the charging coil of the double coil.
  • the beneficial effect is that by performing the laminating operation, the assembled first coil and the second coil can be effectively protected from deformation, thereby facilitating transportation.
  • the present invention also discloses a double coil charging coil manufactured according to the above method, comprising:
  • the first coil has a first spiral trace, a first spacing is left between the windings of the first spiral trace, the first coil includes a first inner end and a first outer end;
  • the second coil has a second helical trace, a second spacing is left between the windings of the second helical trace, and the second coil includes a second inner end and a second outer end;
  • a connecting wire for connecting the first inner end of the first coil with the second outer end of the second coil
  • the first coil is positioned within the second pitch of the second coil
  • the second coil is positioned within the first coil and the second coil pitch of the first coil, the first being located on the same plane.
  • FIG. 1 is a schematic flow chart of a method for manufacturing a double coil charging coil according to an embodiment of the present invention
  • FIG. 2 is a schematic flow chart of a method for manufacturing a double coil charging coil according to another embodiment of the present invention.
  • FIG. 3 is a schematic flow chart of a method for manufacturing a double coil charging coil according to still another embodiment of the present invention.
  • FIG. 4 is a schematic view showing the assembly of a method for manufacturing a double coil charging coil according to an embodiment of the present invention
  • Figure 5 is an enlarged schematic view of a portion A of Figure 4.
  • FIG. 6 is a schematic flow chart showing an assembly operation of a first coil and a second coil in a method for manufacturing a double coil charging coil according to an embodiment of the present invention
  • FIG. 7 is a schematic diagram showing a process of relative pressing of a method for manufacturing a double coil charging coil according to an embodiment of the present invention.
  • FIG. 8 is a schematic diagram of a method for manufacturing a charging coil of a double coil according to an embodiment of the present invention.
  • FIG. 9 is a schematic cross-sectional view showing a product of a double coil charging coil according to an embodiment of the present invention.
  • FIG. 10 is a schematic structural view of a first coil of a double coil charging coil according to an embodiment of the present invention.
  • FIG. 11 is a schematic structural view showing a first inner end of a first coil of a two-coil charging coil folded according to an embodiment of the present invention.
  • Figure 12 is a side elevational view showing the first inner end portion of Figure 11 after being folded.
  • a method of manufacturing a double coil charging coil is provided, as shown in FIG. 1, which includes the following steps;
  • Step S1 preparing the first coil 1, the first coil 1 has a first spiral trace 2, a first spacing 3 is left between the windings of the first helical trace 2, and the first coil 1 comprises a first inner end 4 And a first outer end portion 5;
  • Step S2 preparing the second coil 6, the second coil 6 having the second spiral trace 7, leaving a second spacing 8 between the windings of the second helical trace 7, the second coil 6 comprising the second inner end 9 And a second outer end portion 10;
  • Step S3 the first coil 1 and the second coil 6 are assembled, the first coil 1 is positioned within the second pitch 8 of the second coil 6, and the second coil 6 is positioned at the first of the first coil 1. Within the spacing 3, the first coil 1 and the second coil 6 are placed on the same plane;
  • Step S4 connecting the first inner end portion 4 of the first coil 1 with the second outer end portion 10 of the second coil 6.
  • the present invention uses two coils to be nested in a nested manner, and the gap between the charging coils of the nested assembled double coils is smaller, and the first coil 1 is When it is applied to the wireless charging coil of the mobile phone, the thickness of the wireless charging coil of the mobile phone can be kept to a very small size, so that it can be applied to a limited internal space of the mobile phone. Meet the current thinning requirements of mobile phone manufacturing for mobile phones.
  • the first inner end portion 4 of the first coil 1 and the second outer end portion 10 of the second coil 6 may be connected by a connecting wire 11 by laser welding or electric resistance welding, or by riveting or pressing. Hehe.
  • the connecting line may be a separate connecting line, or the first inner end of the first coil or the second outer end of the second coil may be intentionally left longer when the first coil or the second coil is prepared, and then The lengthened portions are directly folded to form the connecting wires 11 to be connected to each other.
  • the method further includes:
  • Step S21 Applying an insulating coating 20 to any one or both of the first coil 1 and the second coil 6. Because it is a Chinese invention patent application with the publication number CN105934804A, the technical solution of the present invention does not require an adhesive nor a corresponding two laminates, but directly coats the insulating coating 20 to achieve insulation. Handling, or baking paint can also be used for baking varnish. Therefore, there is no problem that the adhesive is displaced under the hot pressure, and the coil is displaced to cause a short circuit.
  • the steps further include:
  • Step S31 Applying the insulating coating 20 to the assembled first coil 1 and second coil 6.
  • the utility model has the beneficial effects that, for the Chinese invention patent application with the publication number of CN105934804A, the technical solution of the invention does not require the adhesive nor the corresponding two laminates, but directly coats the insulating coating 20 Insulation treatment can be achieved, or baking varnish can also be used in the baking process. Therefore, there is no problem that the adhesive is displaced under the hot pressure, and the coil is displaced to cause a short circuit.
  • the insulation treatment can be performed before or after assembly, and only one of the coils can be processed before assembly, and the first coil 1 and the second coil 6 are naturally insulated from each other after the fitting.
  • the first coil 1 and the second coil 6 are formed by any one of stamping and cutting, laser cutting, waterjet cutting, and etching using a copper foil.
  • the utility model has the beneficial effects that the first coil 1 and the second coil 6 can be directly fabricated by using a sheet-shaped copper foil, and the stamping and cutting forming, the laser cutting forming and the water knife can be selected according to the production process, cost and environment requirements. Any of cutting and etching.
  • Step 301 The first coil 1 is adsorbed on the first supporting jig 12, and the first supporting jig 12 is provided with a first adsorption structure 13 corresponding to the position of the first spiral trace 2;
  • Step 302 The second coil 6 is adsorbed on the second supporting jig 14, and the second supporting jig 14 is provided with a second adsorbing structure 15 corresponding to the position of the second spiral trace 7;
  • Step 303 symmetrically disposing the first supporting fixture 12 and the second supporting fixture 14 and performing a relative pressing operation, so that the first coil 1 is positioned within the second spacing 8 of the second coil 6, so that the second coil 6 Positioned within the first pitch 3 of the first coil 1, the first coil 1 and the second coil 6 are nested on each other and on the same plane.
  • the first coil and the second coil cooperate with each other to adjust the matching gap to a minimum of 0-0.2 mm according to the test requirements.
  • the first support fixture 12 is respectively used to adsorb and fix the first coil 1
  • the second support fixture 14 is used to adsorb and fix the second coil 6, so that the two coils can be fixedly positioned, and the position can be very precise, and the two fixtures are
  • the symmetrical arrangement performs the relative pressing operation, so that the first coil 1 and the second coil 6 can be nested on the same plane and on the same plane, and the relative position must not be generated, and the precision is very high.
  • the adsorption structure is a vacuum suction hole or a vacuum suction cup. Good fixing can be achieved by vacuum suction holes or vacuum suction cups to ensure that the coil does not shift. Or other forms of adsorption structures are also possible.
  • first coil 1 When the first coil 1 is adsorbed on the first supporting jig 12 and the second coil 6 is adsorbed on the second supporting jig 14, one or both of the first coil 1 and the second coil 6 are coated and insulated. Coating 20.
  • the beneficial effect is that since one side of the first coil 1 is adsorbed on the first supporting jig 12, the side of the second coil 6 and the side wall of the first spiral trace 2 are bare, and the second coil 6 is also One side is adsorbed on the second supporting fixture 14, and the side of the first coil 1 and the side wall of the second spiral trace 7 are also exposed, so when the insulating coating 20 is applied, for the spiral trace In terms of the cross section, only three faces are coated with the insulating coating 20, and one surface adsorbed on the supporting jig is completely in contact with the insulating coating 20, which ensures that the insulating coating 20 does not enter the support. Between the jig and the coil, the adsorption and fixation of the first coil 1 and the second coil 6
  • the first supporting jig 12 and the second supporting jig 14 are respectively provided with a positioning hole 16 and a positioning pin 17. It is ensured that the first supporting jig 12 and the second supporting jig 14 can be accurately positioned by the cooperation of the positioning hole 16 and the positioning pin 17 during the assembly and assembly, thereby ensuring the accuracy of assembly.
  • the method further includes the steps of:
  • Step S5 The assembled first coil 1 and the second coil 6 are subjected to a lamination operation, and the carrier film 19 with the adhesive glue 18 is applied to either or both sides of the charging coil of the double coil.
  • the beneficial effect is that by performing the laminating operation, the assembled first coil 1 and second coil 6 can be effectively protected from deformation, thereby facilitating transportation.
  • the present invention also discloses a charging coil of a double coil manufactured according to the above method, comprising:
  • the first coil 1 has a first spiral trace 2 with a first spacing 3 between the windings of the first helical trace 2, the first coil 1 comprising a first inner end 4 and a first outer End 5;
  • the second coil 6, the second coil 6 has a second helical trace 7, a second spacing 8 is left between the windings of the second helical trace 7, and the second coil 6 comprises a second inner end 9 and a second outer End 10;
  • the first inner end portion 4 of the first coil 1 is connected to the second outer end portion 10 of the second coil 6.
  • the first inner end portion 4 of the first coil 1 and the second outer end portion 10 of the second coil 6 may be connected by a connecting line 11, and the connecting line 11 may be a separate connecting line 11, or as shown in FIGS. 12, when the first coil 1 or the second coil 6 is prepared, the first inner end of the first coil 1 or the second outer end of the second coil 6 may be intentionally left longer, and then directly The long portions are folded and then used as the connecting wires 11 to be connected to each other.
  • the first coil 1 is positioned within the second pitch 8 of the second coil 6, and the second coil 6 is positioned within the pitch of the first coil 1 and the second coil 6 of the first coil 1, the first being located on the same plane.
  • the gap between the first coil and the second coil can be adjusted to a minimum of 0-0.2 mm according to the test requirement, and the beneficial effect is that the charging coil of the form can satisfy the precision of the product, reduce the product cost, and can Effectively reduce product thickness.

Abstract

本发明公开了一种双线圈的充电线圈及其制造方法，包括如下步骤：准备第一线圈，第一线圈具有第一螺旋迹线，第一螺旋迹线的各绕组之间留有第一间距，第一线圈包括第一内端部和第一外端部；准备第二线圈，第二线圈具有第二螺旋迹线，第二螺旋迹线的各绕组之间留有第二间距，第二线圈包括第二内端部和第二外端部；将第一线圈和第二线圈进行组装操作，将第一线圈定位在第二线圈的第二间距内，并且第二线圈被定位在第一线圈的第一间距内，使第一线圈和第二线圈位于同一平面上；利用连接线将第一线圈的第一内端部与第二线圈的第二外端部相连接。其有益效果是，其厚度可以保持到非常小，从而可以应用于有限的手机内部空间当中，而且充电效率更高。

Description

一种双线圈的充电线圈及其制造方法 技术领域
本发明涉及充电线圈制造领域，尤其涉及一种双线圈的充电线圈制造方法。
背景技术
现有的线圈加工采用铜线缠绕方式，尺寸精度差，充电效率低、散热效果差，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)在塑胶件正面和背面的待处理区域均喷涂一层可激光活化的涂料；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，成本较高，而且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。
公开号为CN105934804A的中国发明专利申请，也公开了一种制作无线充电线圈的方法，包括：
对金属片进行冲压以形成第一线圈，第一线圈具有第一螺旋迹线，第一螺旋迹线限定在各绕组之间的第一间距；
经由第一层压板的粘合剂将第一冲压线圈施加到第一层压板；
对金属片进行冲压以形成第二线圈，第二线圈具有第二螺旋迹线，第二螺旋迹线限定在各绕组之间的第二间距；
经由第二层压板的粘合剂将第二冲压线圈施加到第二层压板；
插入第一冲压线圈和第二冲压线圈以形成平面线圈组件，平面线圈组件具有第一冲压线圈和第二冲压线圈，其中，第一冲压线圈被定位在第二冲压线圈的第二间距内，并且第二冲压线圈被定位在第一冲压线圈的第一间距内，并且第一冲压线圈和第二冲压线圈被定 位在第一层压板与第二层压板之间；
对平面线圈组件进行加热且施压以使第一层压板和第二层压板的粘合剂移位并将第一层压板和第二层压板的粘合剂设置为围绕第一线圈和第二线圈并将第一线圈和第二线圈结合在一起。
这种方式是利用了一种同时具有粘合效果和绝缘效果的粘合剂，这种粘合剂在平时状态下是固化的，可以用于粘合固定，并且加热施压状态下又是流体状可以流动的，从而可以完全的包裹住线圈。但是这种方式仍有不足之处，即粘合剂在流动的过程当中，由于粘合剂具有一定的粘性，所以阻力非常大，容易将线圈带动，由于线圈之间的第一间距和第二间距本身就非常小，相互嵌合后，第一冲压线圈和第二冲压线圈之间的距离其实已经非常小，粘合剂在移位的过程当中，就很容易将第一冲压线圈和第二冲压线圈挤到一起，从而形成短路。
发明内容
本发明的目的是提供一种双线圈的充电线圈制造方法，可以解决上述现有技术问题中的一个或多个。
根据本发明的一个方面，提供了一种双线圈的充电线圈制造方法，其包括如下步骤；
准备第一线圈，第一线圈具有第一螺旋迹线，第一螺旋迹线的各绕组之间留有第一间距，第一线圈包括第一内端部和第一外端部；
准备第二线圈，第二线圈具有第二螺旋迹线，第二螺旋迹线的各绕组之间留有第二间距，第二线圈包括第二内端部和第二外端部；
将第一线圈和第二线圈进行组装操作，将第一线圈定位在第二线圈的第二间距内，并且第二线圈被定位在第一线圈的第一间距内，使第一线圈和第二线圈位于同一平面上；
将第一线圈的第一内端部与第二线圈的第二外端部相连接。
其有益效果是，相对于传统的采用铜线缠绕方式，本发明采用两个线圈相互嵌套的方式来组装在一起，嵌套组装合的双线圈的充电线圈相互之间的间隙更小，而且第一线圈和第二线圈位于同一平面上，应用于手机的无线充电线圈时，其厚度可以保持到非常小，从而可以应用于有限的手机内部空间当中。满足当前手机制造业对手机越来越薄的要求。
在第一线圈和第二线圈进行连接的时候，可以利用连接线将第一线圈的第一内端部与第二线圈的第二外端部相连接，连接的方式可以 采用激光焊接或电阻焊接，也可采用铆合或者压合。连接线可以是单独的连接线，也可以是在准备第一线圈或者第二线圈的时候，将第一线圈的第一内端部或者第二线圈的第二外端部特意留长一些，然后直接将留长的部分进行翻折后，进行相互连接。
在一些实施方式中，在将第一线圈和第二线圈进行组装操作之前，还包括步骤：
对第一线圈和第二线圈中的任意一个或者两个涂布绝缘涂层。其有益效果是，是对于公开号为CN105934804A的中国发明专利申请而言，本发明的技术方案，不需要粘合剂也不需要相应的两块层压板，而是直接进行涂布绝缘涂层即可实现绝缘处理，或者也可以采用烤漆工艺进行烤绝缘漆。所以不会有粘合剂在热压下移位，带动线圈产生移位而产生短路的问题。
在一些实施方式中，在将第一线圈和第二线圈进行组装操作之后，还包括步骤：
对组装后的第一线圈和第二线圈涂布绝缘涂层。其有益效果是，是对于公开号为CN105934804A的中国发明专利申请而言，本发明的技术方案，不需要粘合剂也不需要相应的两块层压板，而是直接进行涂布绝缘涂层即可实现绝缘处理，或者也可以采用烤漆工艺进行烤绝缘漆。所以不会有粘合剂在热压下移位，带动线圈产生移位而产生短路的问题。
绝缘处理可以在组装前或者组装后处理均可以，组装前可以仅对其中一个线圈进行处理，嵌合后第一线圈和第二线圈之间自然也是相互绝缘的。
在一些实施方式中，第一线圈和第二线圈利用铜箔采用冲压切割成型、镭射切割成型、水刀切割成型、蚀刻成型当中的任意一种。其有益效果是，第一线圈和第二线圈可以直接采用片状的铜箔进行制作，可以根据生产工艺、成本、环境的要求，相应的进行选择冲压切割成型、镭射切割成型、水刀切割成型、蚀刻成型当中的任意一种。
在一些实施方式中，在将第一线圈和第二线圈进行组装操作时，采用如下步骤：
将第一线圈吸附于第一支撑治具上，第一支撑治具对应于第一螺旋迹线的位置设有第一吸附结构；
将第二线圈吸附于第二支撑治具上，第二支撑治具对应于第二螺旋迹线的位置设有第二吸附结构；
将第一支撑治具和第二支撑治具对称设置，并进行相对压合操作，使得第一线圈定位在第二线圈的第二间距内，使得第二线圈被定位在第一线圈的第一间距内，使第一线圈和第二线圈相互套嵌并位于同一平面上。
其中，第一线圈与第二线圈配合间隙能够根据测试要求调整配合间隙最小至0-0.2mm。
其有益效果是，分别采用第一支撑治具吸附固定第一线圈，采用第二支撑治具吸附固定第二线圈，这样两个线圈就可以固定定位，位置可以非常的精确，通过两个治具的对称设置进行相对压合操作，就可以使第一线圈和第二线圈相互套嵌并位于同一平面上，而且可以保证一定不会产生相对位置，精确度非常高。
在一些实施方式中，吸附结构为真空吸孔或者真空吸盘。其有益效果是，通过真空吸孔或者真空吸盘，都可以实现良好的固定，保证线圈不会产生位移。
在一些实施方式中，在第一线圈吸附于第一支撑治具上，第二线圈吸附于第二支撑治具上时，对第一线圈和第二线圈中的任意一个或者两个涂布绝缘涂层。其有益效果是，由于第一线圈有一侧吸附于第一支撑治具上，相对于第二线圈的一侧和第一螺旋迹线的侧壁是裸露的，第二线圈也是一侧是吸附于第二支撑治具上，相对于第一线圈的一侧和第二螺旋迹线的侧壁也是裸露的，所以在涂布绝缘涂层时，对于螺旋迹线的断面而言，只有三个面是涂布绝缘涂层，吸附于支撑治具上的一个面是完全不会接触到绝缘涂层的，这可以保证绝缘涂层不会进入到支撑治具和线圈之间，不会影响到第一线圈和第二线圈的吸附固定，可以保证组装的精确性。
在一些实施方式中，第一支撑治具和第二支撑治具上分别设有定位孔和定位销。其有益效果是，保证第一支撑治具和第二支撑治具在进行配合组装时候，可以通过定位孔和定位销的配合，来实现精确定位，保证组装的精确性。
在一些实施方式中，还包括步骤：
对组装后的第一线圈和第二线圈进行覆膜操作，在双线圈的充电线圈任意一侧或者两侧覆上带粘性胶的承载膜。其有益效果是，通过进行覆膜操作，可以有效的保护组装后的第一线圈和第二线圈，防止变形，从而方便进行运输。
同时，本发明还公开了一种根据上述方法制造的双线圈的充电线 圈，包括：
第一线圈，第一线圈具有第一螺旋迹线，第一螺旋迹线的各绕组之间留有第一间距，第一线圈包括第一内端部和第一外端部；
第二线圈，第二线圈具有第二螺旋迹线，第二螺旋迹线的各绕组之间留有第二间距，第二线圈包括第二内端部和第二外端部；及
连接线，用于将第一线圈的第一内端部与第二线圈的第二外端部相连接；
其中，第一线圈定位在第二线圈的第二间距内，第二线圈被定位在第一线圈的第一线圈和第二线圈间距内，第一位于同一平面上。其有益效果是，这种形式的充电线圈，可以满足了产品的精度，降低产品成本，而且可以有效的降低产品厚度。
附图说明
图1为本发明一实施方式的一种双线圈的充电线圈制造方法的流程示意图；
图2为本发明又一实施方式的一种双线圈的充电线圈制造方法的流程示意图；
图3为本发明又一实施方式的一种双线圈的充电线圈制造方法的流程示意图；
图4为本发明一实施方式的一种双线圈的充电线圈制造方法的组装示意图；
图5为图4当中A部分的放大示意图；
图6为本发明一实施方式的一种双线圈的充电线圈制造方法中将第一线圈和第二线圈进行组装操作的流程示意图；
图7为本发明一实施方式的一种双线圈的充电线圈制造方法的相对压合的过程示意图；
图8为本发明一实施方式的一种双线圈的充电线圈制造方法在压合后的示意图；
图9为本发明一实施方式的一种双线圈的充电线圈的产品断面示意图。
图10为本发明一实施方式的一种双线圈的充电线圈的第一线圈的结构示意图；
图11为本发明一实施方式的一种双线圈的充电线圈的第一线圈的第一内端部翻折后的结构示意图。
图12为图11当中第一内端部翻折后的侧视结构图。
具体实施方式
下面结合附图1至12对本发明作进一步详细的说明。
根据本发明的一个方面，提供了一种双线圈的充电线圈制造方法，如图1所示，其包括如下步骤；
步骤S1：准备第一线圈1，第一线圈1具有第一螺旋迹线2，第一螺旋迹线2的各绕组之间留有第一间距3，第一线圈1包括第一内端部4和第一外端部5；
步骤S2：准备第二线圈6，第二线圈6具有第二螺旋迹线7，第二螺旋迹线7的各绕组之间留有第二间距8，第二线圈6包括第二内端部9和第二外端部10；
步骤S3：将第一线圈1和第二线圈6进行组装操作，将第一线圈1定位在第二线圈6的第二间距8内，并且第二线圈6被定位在第一线圈1的第一间距3内，使第一线圈1和第二线圈6位于同一平面上；
步骤S4：将第一线圈1的第一内端部4与第二线圈6的第二外端部10相连接。
相对于传统的采用铜线缠绕方式，本发明采用两个线圈相互嵌套的方式来组装在一起，嵌套组装合的双线圈的充电线圈相互之间的间隙更小，而且第一线圈1和第二线圈6位于同一平面上，应用于手机的无线充电线圈时，其厚度可以保持到非常小，从而可以应用于有限的手机内部空间当中。满足当前手机制造业对手机越来越薄的要求。
可以利用连接线11将第一线圈1的第一内端部4与第二线圈6的第二外端部10相连接，连接的方式可以采用激光焊接或电阻焊接，也可采用铆合或者压合。连接线可以是单独的连接线，也可以是在准备第一线圈或者第二线圈的时候，将第一线圈的第一内端部或者第二线圈的第二外端部特意留长一些，然后直接将留长的部分进行翻折后形成连接线11，进行相互连接。
如图2所示，在将第一线圈1和第二线圈6进行组装操作之前，还包括：
步骤S21：对第一线圈1和第二线圈6中的任意一个或者两个涂布绝缘涂层20。因为是对于公开号为CN105934804A的中国发明专利申请而言，本发明的技术方案，不需要粘合剂也不需要相应的两块 层压板，而是直接进行涂布绝缘涂层20即可实现绝缘处理，或者也可以采用烤漆工艺进行烤绝缘漆。所以不会有粘合剂在热压下移位，带动线圈产生移位而产生短路的问题。
如图3所示，在将第一线圈1和第二线圈6进行组装操作之后，还包括步骤：
步骤S31：对组装后的第一线圈1和第二线圈6涂布绝缘涂层20。其有益效果是，是对于公开号为CN105934804A的中国发明专利申请而言，本发明的技术方案，不需要粘合剂也不需要相应的两块层压板，而是直接进行涂布绝缘涂层20即可实现绝缘处理，或者也可以采用烤漆工艺进行烤绝缘漆。所以不会有粘合剂在热压下移位，带动线圈产生移位而产生短路的问题。
绝缘处理可以在组装前或者组装后处理均可以，组装前可以仅对其中一个线圈进行处理，嵌合后第一线圈1和第二线圈6之间自然也是相互绝缘的。
通常，第一线圈1和第二线圈6利用铜箔采用冲压切割成型、镭射切割成型、水刀切割成型、蚀刻成型当中的任意一种。其有益效果是，第一线圈1和第二线圈6可以直接采用片状的铜箔进行制作，可以根据生产工艺、成本、环境的要求，相应的进行选择冲压切割成型、镭射切割成型、水刀切割成型、蚀刻成型当中的任意一种。
如图6、7、8所示，在将第一线圈1和第二线圈6进行组装操作时，采用如下步骤：
步骤301：将第一线圈1吸附于第一支撑治具12上，第一支撑治具12对应于第一螺旋迹线2的位置设有第一吸附结构13；
步骤302：将第二线圈6吸附于第二支撑治具14上，第二支撑治具14对应于第二螺旋迹线7的位置设有第二吸附结构15；
步骤303：将第一支撑治具12和第二支撑治具14对称设置，并进行相对压合操作，使得第一线圈1定位在第二线圈6的第二间距8内，使得第二线圈6被定位在第一线圈1的第一间距3内，使第一线圈1和第二线圈6相互套嵌并位于同一平面上。
其中，第一线圈与第二线圈配合间隙能够根据测试要求调整配合间隙最小至0-0.2mm。
分别采用第一支撑治具12吸附固定第一线圈1，采用第二支撑治具14吸附固定第二线圈6，这样两个线圈就可以固定定位，位置可以非常的精确，通过两个治具的对称设置进行相对压合操作，就可 以使第一线圈1和第二线圈6相互套嵌并位于同一平面上，而且可以保证一定不会产生相对位置，精确度非常高。
本发明当中，吸附结构为真空吸孔或者真空吸盘。通过真空吸孔或者真空吸盘，都可以实现良好的固定，保证线圈不会产生位移。或者其它形式的吸附结构也是可以的。
在第一线圈1吸附于第一支撑治具12上，第二线圈6吸附于第二支撑治具14上时，对第一线圈1和第二线圈6中的任意一个或者两个涂布绝缘涂层20。其有益效果是，由于第一线圈1有一侧吸附于第一支撑治具12上，相对于第二线圈6的一侧和第一螺旋迹线2的侧壁是裸露的，第二线圈6也是一侧是吸附于第二支撑治具14上，相对于第一线圈1的一侧和第二螺旋迹线7的侧壁也是裸露的，所以在涂布绝缘涂层20时，对于螺旋迹线的断面而言，只有三个面是涂布绝缘涂层20，吸附于支撑治具上的一个面是完全不会接触到绝缘涂层20的，这可以保证绝缘涂层20不会进入到支撑治具和线圈之间，不会影响到第一线圈1和第二线圈6的吸附固定，可以保证组装的精确性。
为了保证定位更加精确，第一支撑治具12和第二支撑治具14上分别设有定位孔16和定位销17。保证第一支撑治具12和第二支撑治具14在进行配合组装时候，可以通过定位孔16和定位销17的配合，来实现精确定位，保证组装的精确性。
在一些实施方式中，还包括步骤：
步骤S5：对组装后的第一线圈1和第二线圈6进行覆膜操作，在双线圈的充电线圈任意一侧或者两侧覆上带粘性胶18的承载膜19。其有益效果是，通过进行覆膜操作，可以有效的保护组装后的第一线圈1和第二线圈6，防止变形，从而方便进行运输。
同时，如图9所示，本发明还公开了一种根据上述方法制造的双线圈的充电线圈，包括：
第一线圈1，第一线圈1具有第一螺旋迹线2，第一螺旋迹线2的各绕组之间留有第一间距3，第一线圈1包括第一内端部4和第一外端部5；及
第二线圈6，第二线圈6具有第二螺旋迹线7，第二螺旋迹线7的各绕组之间留有第二间距8，第二线圈6包括第二内端部9和第二外端部10；
将第一线圈1的第一内端部4与第二线圈6的第二外端部10相 连接。
可以利用连接线11将第一线圈1的第一内端部4与第二线圈6的第二外端部10相连接，连接线11可以是单独的连接线11，或者如图10、11、12所示，也可以是在准备第一线圈1或者第二线圈6的时候，将第一线圈1的第一内端部或者第二线圈6的第二外端部特意留长一些，然后直接将留长的部分进行翻折后作为连接线11，从而进行相互连接。
其中，第一线圈1定位在第二线圈6的第二间距8内，第二线圈6被定位在第一线圈1的第一线圈1和第二线圈6间距内，第一位于同一平面上。其中，第一线圈与第二线圈配合间隙能够根据测试要求调整配合间隙最小至0-0.2mm，其有益效果是，这种形式的充电线圈，可以满足了产品的精度，降低产品成本，而且可以有效的降低产品厚度。
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. 一种双线圈的充电线圈制造方法，其特征在于，包括如下步骤：
    准备第一线圈，所述第一线圈具有第一螺旋迹线，所述第一螺旋迹线的各绕组之间留有第一间距，所述第一线圈包括第一内端部和第一外端部；
    准备第二线圈，所述第二线圈具有第二螺旋迹线，所述第二螺旋迹线的各绕组之间留有第二间距，所述第二线圈包括第二内端部和第二外端部；
    将第一线圈和第二线圈进行组装操作，将第一线圈定位在所述第二线圈的所述第二间距内，并且所述第二线圈被定位在所述第一线圈的所述第一间距内，使第一线圈和第二线圈位于同一平面上；
    将第一线圈的第一内端部与第二线圈的第二外端部相连接。
  2. 根据权利要求1的一种双线圈的充电线圈制造方法，其特征在于，在将第一线圈和第二线圈进行组装操作之前，还包括步骤：
    对第一线圈和第二线圈中的任意一个或者两个涂布绝缘涂层。
  3. 根据权利要求1的一种双线圈的充电线圈制造方法，其特征在于，在将第一线圈和第二线圈进行组装操作之后，还包括步骤：
    对组装后的第一线圈和第二线圈涂布绝缘涂层。
  4. 根据权利要求1的一种双线圈的充电线圈制造方法，其特征在于，所述第一线圈和第二线圈利用铜箔采用冲压切割成型、镭射切割成型、水刀切割成型、蚀刻成型当中的任意一种。
  5. 根据权利要求1的一种双线圈的充电线圈制造方法，其特征在于，在将第一线圈和第二线圈进行组装操作时，采用如下步骤：
    将第一线圈吸附于所述第一支撑治具上，所述第一支撑治具对应于所述第一螺旋迹线的位置设有第一吸附结构；
    将第二线圈吸附于所述第二支撑治具上，所述第二支撑治具对应于所述第二螺旋迹线的位置设有第二吸附结构；
    将第一支撑治具和第二支撑治具对称设置，并进行相对压合操 作，使得第一线圈定位在所述第二线圈的所述第二间距内，使得第二线圈被定位在所述第一线圈的所述第一间距内，使第一线圈和第二线圈相互套嵌并位于同一平面上；
    其中，第一线圈与第二线圈配合间隙能够根据测试要求调整配合间隙最小至0-0.2mm。
  6. 根据权利要求5的一种双线圈的充电线圈制造方法，其特征在于，所述吸附结构为真空吸孔或者真空吸盘。
  7. 根据权利要求5的一种双线圈的充电线圈制造方法，其特征在于，在第一线圈吸附于所述第一支撑治具上，第二线圈吸附于所述第二支撑治具上时，对第一线圈和第二线圈中的任意一个或者两个涂布绝缘涂层。
  8. 根据权利要求5的一种双线圈的充电线圈制造方法，其特征在于，第一支撑治具和第二支撑治具上分别设有定位孔和定位销。
  9. 根据权利要求1的一种双线圈的充电线圈制造方法，其特征在于，还包括步骤：
    对组装后的第一线圈和第二线圈进行覆膜操作，在双线圈的充电线圈任意一侧或者两侧覆上带粘性胶的承载膜。
  10. 一种根据权利要求1至9中任意一项制造的双线圈的充电线圈，包括：
    第一线圈，所述第一线圈具有第一螺旋迹线，所述第一螺旋迹线的各绕组之间留有第一间距，所述第一线圈包括第一内端部和第一外端部；及
    第二线圈，所述第二线圈具有第二螺旋迹线，所述第二螺旋迹线的各绕组之间留有第二间距，所述第二线圈包括第二内端部和第二外端部；
    第一线圈的第一内端部与第二线圈的第二外端部相连接；
    其中，所述第一线圈定位在所述第二线圈的所述第二间距内，所述第二线圈被定位在所述第一线圈的所述第一线圈和所述第二线圈间距内，所述第一位于同一平面上。
PCT/CN2018/088419 2018-05-18 2018-05-25 一种双线圈的充电线圈及其制造方法 WO2019218392A1 (zh)

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