阅读说明：本技术 无线充电线圈组件的制备方法和制备装置 (Preparation method and preparation device of wireless charging coil assembly ) 是由 吴自强 郭永江 陈晨 于 2019-09-25 设计创作，主要内容包括：本发明揭示了一种无线充电线圈组件的制备方法,其包括如下步骤：提供承载体,所述承载体具有相对设置的内凹弧面及外凸弧面的磁芯；提供等价弧工件,所述等价弧工件具有相对设置的等价弧面和外表面；使所述等价弧工件的外表面面对所述承载体的内凹弧面；对磁芯和等价弧工件进行绕线并在形成线圈后移开等价弧工件；推动线圈使线圈与磁芯的内凹弧面贴合,从而实现线圈和磁芯的紧密贴合另,本发明还揭示一种无线充电线圈组件的制备装置。(The invention discloses a preparation method of a wireless charging coil assembly, which comprises the following steps: providing a bearing body, wherein the bearing body is provided with a magnetic core with an inner concave cambered surface and an outer convex cambered surface which are oppositely arranged; providing an equivalent arc workpiece, wherein the equivalent arc workpiece is provided with an equivalent arc surface and an outer surface which are oppositely arranged; the outer surface of the equivalent arc workpiece faces the concave arc surface of the bearing body; winding the magnetic core and the equivalent arc workpiece and moving the equivalent arc workpiece away after a coil is formed; the coil is pushed to enable the coil to be attached to the concave cambered surface of the magnetic core, so that the coil and the magnetic core are tightly attached to each other.)

1. A preparation method of a wireless charging coil assembly is characterized by comprising the following steps:

providing a bearing body (1), wherein the bearing body (1) is provided with a magnetic core (11) with an inner concave cambered surface (111) and an outer convex cambered surface (112) which are oppositely arranged;

providing an equivalent arc workpiece (3), wherein the equivalent arc workpiece (3) is provided with an equivalent arc surface (31) and an outer surface (32) which are oppositely arranged;

making the outer surface (32) of the equivalent arc workpiece (3) face the inner concave arc surface (111) of the bearing body (1);

winding the magnetic core (11) and the equivalent arc workpiece (3) and removing the equivalent arc workpiece (3) after the coil is formed;

the coil (2) is pushed to enable the coil (2) to be attached to the concave cambered surface (111) of the magnetic core (11).

2. The method of claim 1, wherein: the equivalent arc surface (31) of the equivalent arc workpiece (3) corresponds to the concave arc surface (111) of the bearing body (1).

3. The method of claim 1, wherein the applying is continued with heating.

4. A method according to any one of claims 1 to 3, wherein the coil (2) is pushed by a shaping means (4), said shaping means (4) having a shaping arc (41) which can be brought into full abutment with said concave arc (111).

5. The method of any one of claims 1-3, further comprising the steps of: the carrier (1) is rotated and the coil (2) is arranged on the other magnetic core (11) according to the same steps.

6. A method of manufacturing as claimed in any one of claims 1 to 3, characterized in that after the windings of the plurality of magnetic cores (11) have been completed, the individual coils (2) are shaped.

7. A device (200) for preparing a wireless charging coil assembly, comprising:

the positioning mechanism (5) comprises a positioning piece (51) for positioning the bearing body (1) and an equivalent arc workpiece (3) for replacement, the equivalent arc workpiece (3) is provided with an equivalent arc surface (31) and an outer surface (32) which are oppositely arranged, and the bearing body (1) comprises a magnetic core (11) which is provided with an inner concave arc surface (111) and an outer convex arc surface (112) which are oppositely arranged;

a winding mechanism (6) comprising a needle (61) for winding the magnetic core (11) and the equivalent arc surface (31) of the carrier (1) to form a coil;

the shaping mechanism (4) comprises a shaping arm (42) used for pushing the coil (2) to be attached to the concave cambered surface (111), and the shaping arm (42) is arranged in a telescopic mode relative to the positioning mechanism (5).

8. The manufacturing apparatus according to claim 7, wherein the equivalent arc surface (31) of the equivalent arc workpiece (3) corresponds to the concave arc surface (111) of the carrier (1).

9. The device according to claim 7, wherein the positioning mechanism (5) further comprises a rotating member for driving the positioning member (51) to rotate.

10. The manufacturing apparatus according to claim 7, wherein the positioning mechanism (5) further includes a lifting member that drives the equivalent arc workpiece (3) to be lifted.

11. Preparation device according to claim 7, characterised in that the free end of the reshaping arm (4) is provided with a reshaping curve (41) which can be brought into full abutment with the concave curve (111).

12. The manufacturing apparatus of any one of claims 7 to 11, further comprising a heating device comprising a heat gun that heats the coil during shaping.

Technical Field

The invention relates to a preparation method and a preparation device of a wireless charging coil assembly, and belongs to the technical field of wireless charging.

Background

As electric power becomes a main energy source of daily products, wireless charging technology is widely used in various fields due to its advantage of convenient use. The way of transferring power between two induction coils using the near-field induction principle is a wireless charging technology that is quite popular at present. The wireless charging industry chain comprises the steps of scheme design, power supply chips, magnetic materials, transmission coils, module manufacturing and the like. The transmission coil needs to be built in the terminal, and besides the requirements for low loss and light weight, the shapes of the transmission coil also tend to be diversified due to the limitation of different wireless charging structures. However, when a coil is wound on a magnetic core having a concave surface to form a profile transmission coil, the conventional method for winding the coil is limited, and the coil and the magnetic core cannot be tightly attached.

Disclosure of Invention

The invention aims to provide a preparation method of a wireless charging coil assembly, which is used for realizing the close fit of a coil and a magnetic core.

In order to achieve the purpose, the invention adopts the following technical scheme:

a preparation method of a wireless charging coil assembly comprises the following steps:

providing a bearing body, wherein the bearing body is provided with a magnetic core with an inner concave cambered surface and an outer convex cambered surface which are oppositely arranged;

providing an equivalent arc workpiece, wherein the equivalent arc workpiece is provided with an equivalent arc surface and an outer surface which are oppositely arranged;

the outer surface of the equivalent arc workpiece faces the concave arc surface of the bearing body;

winding the magnetic core and the equivalent arc workpiece and moving the equivalent arc workpiece away after a coil is formed;

the coil is pushed to enable the coil to be attached to the concave cambered surface of the magnetic core.

As a further improved technical scheme of the invention, the equivalent arc surface of the equivalent arc workpiece corresponds to the concave arc surface of the bearing body.

As a further improved technical scheme of the invention, the laminating process is continuously heated.

As a further improved technical scheme of the invention, the coil is pushed by a shaping mechanism which is provided with a shaping cambered surface which can be completely attached to the concave cambered surface.

As a further improvement of the present invention, the carrier is rotated and the coil is provided to the other core in the same manner as described above.

As a further improved technical scheme of the invention, after the plurality of magnets are respectively wound, each coil is shaped.

The invention also discloses a device for preparing the wireless charging coil assembly, which comprises:

the positioning mechanism comprises a positioning piece for positioning the bearing body and an equivalent arc workpiece for replacement, the equivalent arc workpiece is provided with an equivalent arc surface and an outer surface which are oppositely arranged, and the bearing body comprises a magnetic core provided with an inner concave arc surface and an outer convex arc surface which are oppositely arranged;

the winding mechanism comprises a needle head for winding the magnetic core and the equivalent cambered surface of the carrier to form a coil;

and the shaping mechanism comprises a shaping arm used for pushing the coil to be attached to the concave cambered surface, and the shaping arm is arranged in a telescopic manner relative to the positioning mechanism.

As a further improved technical scheme of the invention, the equivalent arc surface of the equivalent arc workpiece corresponds to the concave arc surface of the bearing body.

As a further improved technical solution of the present invention, the positioning mechanism further includes a rotating member for driving the positioning member to rotate.

As a further improved technical scheme of the invention, the positioning mechanism further comprises a lifting piece for driving the equivalent arc workpiece to lift.

As a further improved technical scheme of the invention, the free tail end of the shaping arm is provided with a shaping cambered surface which can be completely attached to the concave cambered surface.

The improved technical scheme of the invention also comprises a heating device, wherein the heating device comprises a hot air gun for heating the coil during shaping.

Compared with the prior art, the preparation method has the beneficial effects that: and an equivalent arc workpiece is adopted, and the coil is shaped after being wound, so that the coil is tightly attached to the magnetic core.

Drawings

Figure 1 is a schematic diagram of the structure of a wireless charging coil assembly of the present invention.

Fig. 2 is another angle structure diagram of fig. 1.

Fig. 3 is a schematic structural diagram of a carrier of a wireless charging coil assembly of the present invention.

Fig. 4 is a schematic flow chart of a method for manufacturing a wireless charging coil assembly according to the present invention.

Fig. 5 is a schematic diagram of a wireless charging coil assembly of the present invention during its manufacture, wherein the coil is shown in two states.

Fig. 6 is a schematic structural diagram of a device for preparing a wireless charging coil assembly according to the present invention.

Fig. 7 is a partial structural schematic view of fig. 6.

Fig. 8 is a partial structural schematic view of fig. 6.

Detailed Description

Referring to fig. 1 to 3, the present invention discloses a wireless charging coil assembly 100, which includes a carrier 1 and a coil 2; the carrier 1 includes the magnetic core 11 that has indent cambered surface 111, and coil 2 winds along indent cambered surface 111 and locates on magnetic core 11, and magnetic core 11 that has indent cambered surface 111 and coil 2 along indent cambered surface 111 coiling can break through more structural constraint, do not be restricted by wireless charging structural constraint, and its application scope is wider.

Preferably, the magnetic core 11 is substantially brow-shaped, and further includes an outer convex arc surface 112 opposite to the inner concave arc surface 111, and a connection arc surface 113 respectively connected to the inner concave arc surface 111 and the outer convex arc surface 112 at two sides.

Preferably, the carrier 1 includes a ring-shaped base 12 and a magnetic core 11 protruding from the ring-shaped base 12, and the magnetic cores 11 are symmetrically distributed along the ring-shaped base 12. The two magnetic cores 11 extend along the annular bending and are distributed on two sides of the annular base 12 at 180 degrees, and the two magnetic cores 11 are symmetrically distributed.

Preferably, the material of the carrier is a magnetic core material such as ferrite, and the annular base 12 and the magnetic core 11 of the carrier are of an integral structure.

Preferably, the annular base 12 has a chord 121, and the chord 121 has a straight edge thereon, which facilitates the forming and fixing of the annular base.

The magnetic core 11 with the concave arc surface 111 can adapt to more structural occasions, but the winding of the coil 2 is difficult, the invention discloses the preparation method of the wireless charging coil assembly, the process is simple, the stability is good, and the magnetic core 11 and the coil 2 are tightly attached.

Specifically, referring to fig. 4, and also referring to fig. 1 to 3 and fig. 5 to 8, a method for manufacturing a wireless charging coil assembly 100 includes the following steps:

the method comprises the following steps: providing a carrier 1, wherein the carrier 1 has a magnetic core 11 with an inner concave arc surface 111 and an outer convex arc surface 112 arranged oppositely. The toroidal coil 2 of the carrier 11 is positioned and the magnetic core 11 is exposed to a set position.

Step two: an equivalent arc workpiece 3 is provided, the equivalent arc workpiece 3 having an equivalent arc face 31 and an outer face 32 disposed opposite to each other. The equivalent arc surface 31 of the equivalent arc workpiece 3 corresponds to the concave arc surface 111 of the carrier 1, and the correspondence means that the equivalent arc surface 31 corresponds to the radian of the concave arc surface 111, and may be a mirror image relationship, for example. The equivalent arc surface 31 has arcs of the same curvature as the concave arc surface 111, except that one is disposed in a convex shape and one is disposed in a concave shape.

Step three: the outer surface 32 of the equivalent arc workpiece 3 is made to face the concave arc surface 111 of the carrier 1. Thus, the inner concave arc shape of the magnetic core can be changed into the outer convex arc shape by utilizing the equivalent arc workpiece 3, so that the winding can be smoothly carried out.

Step four: winding the magnetic core 11 and the equivalent arc workpiece 3, and moving the equivalent arc workpiece 3 away after the coil 2 is formed; and winding is carried out on the convex arc surface 112 of the magnetic core 11, the connecting arc surfaces 113 at two sides and the equivalent arc surface 31 of the equivalent arc workpiece 3, the equivalent arc workpiece 3 is moved away after the winding is finished, and then the coil 2 originally positioned on the equivalent arc workpiece 3 is suspended.

Step five: the coil 2 is pushed to make the coil 2 fit with the concave cambered surface 111 of the magnetic core 11. Because the equivalent arc surface 31 of the equivalent arc workpiece 3 is arranged, the coil wound on the equivalent arc surface 31 is equivalent to the coil wound on the concave arc surface 111, and thus, after the equivalent arc workpiece 3 is removed, the coil 2 is pushed to be attached to the concave arc surface 111, and complete attachment can be realized.

The preparation method also comprises the following steps: continuously heat laminating process for coil 2 and the inseparable laminating of magnetic core 11 realize coil 2 and magnetic core 11's zero clearance fit, thereby make wireless charging coil module 100's stability better, reduce the loss, improve wireless efficiency of charging.

Preferably, the shaping mechanism 4 is used for pushing the coil 2, and the shaping mechanism 4 is provided with a shaping arc surface 41 which can be completely attached to the concave arc surface 111, so that the coil 2 which is originally wound on the equivalent arc workpiece 3 is suspended due to the removal of the equivalent arc workpiece 3, the suspended coil is pushed by the shaping arc surface 4, the suspended coil 2 is clamped between the concave arc surface 111 and the shaping arc surface 41, the coil 2 which is originally suspended can be tightly attached to the concave arc surface 111 through continuous heating, and the gapless fit between the coil 2 and the magnetic core 11 is realized. Because the equivalent arc surface 31 is equivalent to the concave arc surface 111 and has a mirror image relationship with the concave arc surface 111, the coil 2 originally wound around the equivalent arc surface 111 can be just attached to the concave arc surface 111, so that the coil 2 is completely wound around the magnetic core 11.

The further preparation method comprises the following steps: the carrier 1 is rotated and the coil 2 is arranged on the other core 11 in the same manner as described above. The annular base 12 is rotated 180 degrees, another magnetic core 11 is exposed to a set position, the equivalent arc workpiece 3 is made to be close to another magnetic core 11, the equivalent arc surface 31 is arranged corresponding to the concave arc surface 111, the concave arc surface is changed into a convex arc surface, then the magnetic core 11 and the equivalent arc surface 31 are wound, the equivalent arc workpiece 3 is moved away after winding is completed, and the shaping mechanism 4 is used for attaching the suspended coil 2 to the concave arc surface 111. Thereby completing the manufacture of the wireless charging coil assembly 100.

As described above, the coil 2 is converted from the concave arc surface to the convex arc surface through the equivalent arc workpiece 3, and after the winding step is completed, the coil 2 is converted into the preset concave arc surface through the shaping mechanism 4, so that the coil with the concave arc surface can be successfully prepared, and the problem that the coil with the concave arc surface is difficult to prepare in the prior art is solved.

In other embodiments, after the plurality of magnetic cores 11 are wound, the coils 2 are shaped. That is, the winding process may be performed first, and after all the winding processes are completed, the shaping process may be performed. In the case of a plurality of magnetic cores, the order of winding and shaping is not limited, and examples of the order include: the shaping can be finished one by one or several by several, or can be finished one by one or at the same time after all the windings are finished.

Referring to fig. 5 to 8, the present invention further provides a device 200 for manufacturing a wireless charging coil assembly 100, which includes a positioning mechanism 5, a winding mechanism 6 and a shaping mechanism 4. The positioning mechanism 5 comprises a positioning piece 51 for positioning the bearing body 1 and an equivalent arc workpiece 3 for replacement, the equivalent arc workpiece 3 has an equivalent arc surface 31 and an outer surface 32 which are oppositely arranged, and the bearing body 1 comprises a magnetic core 11 which is oppositely arranged and has an inner concave arc surface 111 and an outer convex arc surface 112. Winding mechanism 6 includes a needle 61 for winding core 11 and equivalent arc 31 of carrier 1 to form a coil. The shaping mechanism 4 comprises a shaping arm 42 for pushing the coil 2 to be attached to the concave cambered surface 111, and the shaping arm 42 is telescopically arranged relative to the positioning mechanism 5.

Preferably, the equivalent arc surface 31 of the equivalent arc workpiece 3 corresponds to the concave arc surface 111 of the carrier 1. The correspondence refers to the radian correspondence of the equivalent arc surface 31 and the concave arc surface 111, and may be a mirror image relationship, for example. The equivalent arc workpiece 3 is arranged close to the magnetic core 11 of the bearing body 1, the outer surface 32 of the equivalent arc workpiece 3 is arranged opposite to the concave cambered surface 111 of the magnetic core, and the equivalent cambered surface 31 is arranged corresponding to the concave cambered surface 111 in a mirror image mode.

Preferably, the positioning mechanism 5 further includes a rotating member (not shown) for driving the positioning member 51 to rotate, and the rotating member is configured to rotate the annular base 12 180 degrees after the winding of the one magnetic core 11 is completed, so as to perform the winding of the other magnetic core 11.

Preferably, the positioning mechanism 5 further includes a lifting member (not shown) for driving the equivalent arc workpiece to be lifted and lowered. After the annular base 12 is positioned, the lifting member drives the equivalent arc workpiece 3 to ascend until the equivalent arc surface 31 of the equivalent arc workpiece 3 is arranged corresponding to the concave arc surface 111 of the magnetic core 11. After the winding is finished, the equivalent arc workpiece 3 is driven to descend by the price increasing piece, so that the coil wound on the equivalent arc surface 31 originally is suspended.

Preferably, the free end of the shaping arm 42 is provided with a shaping arc surface 41 which can completely fit with the concave arc surface 111. The shaping arm 42 is retracted after the shaping arm 42 is continuously extended to push the suspended coil 2 to the concave arc surface 111.

Preferably, the manufacturing apparatus 200 further includes a heating device (not shown) including a heat gun for heating the coil 2 during the shaping. The continuous heating makes the coil closely attached to the magnetic core 11, and the gapless fit of the coil 2 and the magnetic core 11 is realized.

When the wireless charging coil assembly 100 is manufactured, the bearing body 1 is positioned on the positioning piece 51 of the positioning mechanism 5, and the lifting piece drives the equivalent arc workpiece 3 to ascend until the iso-cambered surface 31 of the equivalent arc workpiece 3 is arranged corresponding to the concave cambered surface 111 of the magnetic core 11; then, the needle 61 moves in X, Y, Z coordinates, paying off and winding on the magnetic core 11 and the equivalent arc surface 31, and after the winding is finished, the lifting piece drives the equivalent arc workpiece 3 to descend; then, the shaping mechanism 4 is turned over, the shaping arm 42 extends out of the magnetic core 11 and pushes the suspended coil to approach the concave arc surface 111, and a hot air gun of the heating device continuously heats in the whole pushing process, so that the coil 2 is tightly attached to the concave arc surface 111, and the whole coil 2 is tightly attached to the magnetic core 11. After the winding of the magnetic core on one side is completed, the rotor rotates the ring base 12 by 180 degrees, and the winding on the other side is performed.

In other embodiments, after the winding of one magnetic core 11 is completed, the rotating member rotates the annular base 12 by 180 degrees, the other equivalent arc workpiece 3 is lifted and wound, the equivalent arc workpiece 3 is lowered, and after the winding of both magnetic cores 11 is completed, the shaping mechanism 4 performs shaping.

In other embodiments, each magnetic core 11 is correspondingly provided with one equivalent arc workpiece 3, and after all windings are completed, all equivalent arc workpieces 3 are removed and then are shaped.

As described above, the manufacturing apparatus of the present invention can transform the coil 2 from the concave arc surface to the convex arc surface through the equivalent arc workpiece 3, and can transform the coil 2 to the preset concave arc surface through the shaping mechanism 4, so that the manufacturing apparatus of the present invention can successfully manufacture the coil having the concave arc surface, and overcomes the problem that the coil having the concave arc surface is difficult to manufacture in the prior art.

The invention adopts equivalent arc and shaping process, and can perform winding of the special-shaped magnetic core with the concave surface, thereby forming the special-shaped wireless charging coil assembly and leading the shape of the coil to be in a diversified trend; and continuously heat in the plastic process for coil and magnetic core zero clearance closely cooperate, reduce loss and frivolous, and the yield is higher, and wireless charging coil subassembly's stability is higher, improves charge efficiency.

The above embodiments are only used for illustrating the present invention and not for limiting the technical solutions described in the present invention, and the understanding of the present specification should be based on the technical personnel in the technical field, such as the directional descriptions of "front", "back", "left", "right", "upper", "lower", etc., although the present specification has described the present invention in detail with reference to the above embodiments, the ordinary skilled in the art should understand that the technical personnel in the technical field can still make modifications or equivalent substitutions on the present invention, and all the technical solutions and modifications thereof without departing from the spirit and scope of the present invention should be covered in the claims of the present invention.