Systems and methods for utilizing laser cutting and chemical etching in manufacturing wireless power antennas

A method for manufacturing an antenna for a wireless power transfer system, the antenna including a multi-layered coil having, at least, a first layer and a second layer, the method comprising:

• providing a first sheet of a conductive metal, the first sheet defining a first area;
• providing a second sheet of a conductive metal, the second sheet defining a second area;
• applying an etch resistant coating on a first coil area within the first area;
• applying an etch resistant coating on a second coil area within the second area;
• laser cutting the first sheet within the first coil area, based on a first laser cutting path, the first laser cutting path defining a first geometry for a first plurality of turns for a first layer of the multi-layered coil, the first geometry configured for one or more of transmission of wireless power signals, receipt of wireless power signals, or combinations thereof;
• laser cutting the second sheet within the second coil area, based on a second laser cutting path, the second laser cutting path defining a second geometry for a second plurality of turns for a second layer of the multi-layered coil, the second geometry configured for one or more of transmission of wireless power signals, receipt of wireless power signals, or combinations thereof;
• substantially exposing the first sheet to an etching solution, the etching solution substantially removing first portions of the conductive metal from a substrate of the antenna to define, at least, first turn gaps between at least two of the first plurality of turns;
• and
• substantially exposing the second sheet to an etching solution, the etching solution substantially removing second portions of the conductive metal from the substrate to define, at least, second turn gaps between at least two of the second plurality of turns.

An antenna for a wireless power transfer system, the antenna comprising:

• a coil, the coil including a first layer, the first layer defining a first plurality of turns, the first plurality of turns formed by:
• providing a first sheet of a conductive metal, the first sheet defining a first area,
• applying an etch resistant coating on a coil area within the first area,
• laser cutting the first sheet within the coil area, based on a first laser cutting path, the first laser cutting path defining a first geometry for the plurality of turns for the first layer of the coil, the first geometry configured for one or more of transmission of wireless power signals, receipt of wireless power signals, or combinations thereof, and
• substantially exposing the first sheet to an etching solution, the etching solution substantially removing first portions of the conductive metal from a substrate of the antenna to define, at least, first turn gaps between at least two of the first plurality of turns.