Method and Apparatus for Manufacturing Flat Coils

Simple SummaryContent extracted from patent full text and abstract with AI.

This invention describes a method and device for producing nearly two-dimensional flat coils using two cover plates and an interchangeable former, which can be flexibly adapted to create coils of various geometries. The former is clamped between the plates, and the coil conductor is wound around it, with the wound turns locally fixed through cut-outs in the plates. The process eliminates the need for complex form parts, increases manufacturing flexibility, and enables parallel production of multiple coils.

Use CasesContent extracted from patent full text and abstract with AI.

• Wireless inductive charging systems for electric vehicles, particularly in road infrastructure
• Production of flat coils for contactless energy transfer in industrial automation, robotics, or transport systems
• Manufacturing flat coils of varying geometries for sensors, wireless power modules, and electromagnetic applications
• Implementation in urban environments for aesthetically integrated charging or energy transfer solutions
• Efficient serial or batch manufacturing of custom flat coils for electronics and power transmission

BenefitsContent extracted from patent full text and abstract with AI.

• Flexible and simple method to produce flat coils of various shapes and sizes
• Parallel production capability, increasing throughput and manufacturing efficiency
• Elimination of complex and expensive form parts, lowering costs
• Enhanced process security and reliability due to simplified handling and precise fixing of coil turns
• Enables robust, high-performance coils suitable for large-scale inductive charging (e.g., roadways for EVs)
• Modular design allows for integration of electronic or magnetic components directly during coil manufacture
• Local fixing and easy demolding streamline post-processing and quality control

Technical Classifications (CPCs)

Inventors & Applicants

Patent Abstract

The invention relates to a method for producing substantially two-dimensional flat coils (28), wherein at least two cover plates (2, 3) that each have a cover surface (20) and a former (4) having a former surface (21) that is smaller than the cover surfaces (20) are provided, wherein the former (4) is releasably clamped between the two cover plates (2, 3), such that at least some sections of lateral support surfaces (10) are formed by projecting sections (9) of the cover plates (2, 3), wherein a coil conductor (25) for the geometry of the flat coil (28) is wound along the circumference of the former (4) between the cover plates (2, 3), and wherein the wound coil conductors (25) are fixed locally relative to one another through cut-outs (16) in at least one of the cover plates (2, 3). The invention further relates to a corresponding winding device (1, 11, 22).