CN103714938A - Magnetic flux guide component - Google Patents

Magnetic flux guide component Download PDF

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Publication number
CN103714938A
CN103714938A CN201310145865.2A CN201310145865A CN103714938A CN 103714938 A CN103714938 A CN 103714938A CN 201310145865 A CN201310145865 A CN 201310145865A CN 103714938 A CN103714938 A CN 103714938A
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China
Prior art keywords
layer
heat
conducting layer
permeability
lamination
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CN201310145865.2A
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Chinese (zh)
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J·K·施万内克
K·J·特纳
B·C·梅斯
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Access Business Group International LLC
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Access Business Group International LLC
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Publication of CN103714938A publication Critical patent/CN103714938A/en
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    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01FMAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F27/00Details of transformers or inductances, in general
    • H01F27/08Cooling; Ventilating
    • H01F27/22Cooling by heat conduction through solid or powdered fillings
    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01FMAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F27/00Details of transformers or inductances, in general
    • H01F27/24Magnetic cores
    • H01F27/25Magnetic cores made from strips or ribbons
    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01FMAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F41/00Apparatus 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
    • H01F41/02Apparatus 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
    • H01F41/0206Manufacturing of magnetic cores by mechanical means
    • H01F41/0213Manufacturing of magnetic circuits made from strip(s) or ribbon(s)
    • H01F41/0226Manufacturing of magnetic circuits made from strip(s) or ribbon(s) from amorphous ribbons

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  • Engineering & Computer Science (AREA)
  • Power Engineering (AREA)
  • Manufacturing & Machinery (AREA)
  • Laminated Bodies (AREA)
  • Shielding Devices Or Components To Electric Or Magnetic Fields (AREA)

Abstract

The invention relates to a magnetic flux guide component. A laminated flux guide with a cover layer and a thermally conductive layer disposed on opposite sides of a plurality of alternating layers of high permeability and electrically insulating materials is provided. The thermally conductive layer may be a metal, such as aluminum. The present invention also provides a method of manufacturing including the general steps of: providing a plurality of rolls of high permeability material; providing a roll of thermally conductive material, providing a roll of cover material; applying an electrically insulating adhesive between adjacent layers of the high permeability material; feeding the high permeability material layers with the applied adhesive into pressure rollers to form a pre-laminate; feeding the thermally conductive layer, the pre-laminate and the cover layer into pressure rollers to join them under pressure into a final laminate and cutting the final laminate into the desired shape.

Description

Magnetic flux director assembly
Technical field
The present invention relates to the method for magnetic flux guider and manufacture magnetic flux guider.
Background technology
Magnetic flux guider (magnetic flux guide is called as flux concentrator, flux focalizer, flux booster, flux shunt, flow controller, flux reflector and other titles sometimes) normally known and flowing of being used to controlling magnetic field in the application such as induction heating and induced power delivery applications.Flux director (flux guide) is typically by providing high magnetic permeability flow path to contribute to flowing of controlling magnetic field.By high magnetic permeability flow path is provided, flux director provides a minimum impedance and can effectively attract the path in more magnetic fields.This can strengthen magnetic field in specific region, and can help to improve power efficiency.In the situation that there is no flux director, magnetic field more may be disseminated and be intersected with the surrounding of any conduction.In some cases, flux shield can be the magnetic flux concentrator of a type.
As mentioned above, flux director is typically formed by the material with relative high magnetic permeability.Diversified high-permeability material is available in flux director for us.For example, soft magnetic material, such as ferrite (ferrite), is often used in manufacture flux director.Ferrite flux concentrator is compact texture, typically by the oxide of iron oxide and one or more metals (such as nickel, zinc or manganese) or carbonate are mixed and made.The major defect of ferrite flux concentrator is when manufactured with thin cross section, and they are often frangible and tend to bending.Therefore ferrite also typically has low saturation flux density and easily becomes saturatedly, and than air, more there is to permeability in magnetic field no longer significantly exist in other magnetic fields thus in the situation that, and this may be less desirable in some applications.
Sometimes the another kind of soft magnetic material that is used to manufacture flux concentrator is magnetodielectric material (magneto dielectric material, MDM).These materials are by soft magnetic material and serve as the binding agent of particle and the dielectric substance of electrical insulator is made.MDM flux concentrator occurs with two kinds of forms: shapable and solid.Shapable MDM is putty-like and is expected the geometry that is molded as applicable coil.The MDM of solid produces by pressed metal powder and binding agent and follow-up heat treatment.The characteristic of MDM flux concentrator especially changes based on binding agent percentage.Typically, magnetic permeability is higher more at least for binding agent.Yet in traditional layout, binding agent has still less changed into the contact of more metal to metal, and therefore between the operating period of flux concentrator, formed more vortex flow.Although MDM flux concentrator can be manufactured with thin profile, owing to changing the competitive effect (competing effects) of binding agent percentage, be difficult to the MDM flux concentrator that manufacture has magnetic characteristic and the thermal characteristics of all expectations.
Although soft magnetic material discussed above provides than the higher magnetic permeability of surrounding air and effective flux director normally, in very eurypalynous application, have that more the material of high magnetic permeability may be more effective.For example, in conjunction with " high-permeability material ", (be that relative permeability surpasses 100, there is the representative value in the scope of 1000-70000+) alternative soft magnetic material, such as various types of amorphous metals, metal glass and nanocrystal metal, be suitable for being used in the manufacture of high-performance flux director.Although these materials can be compared other soft magnetic materials significant gain is provided aspect magnetic permeability, they have suffered some potential shortcomings.First, they are high conductivity normally, and this may cause the generation of vortex flow and less desirable heating in material.In order to solve heating misgivings, developed the flux director of lamination.Typical lamination flux director 200 comprise by a plurality of thin layers of thin electrical insulating material 204 high-permeability material 202 separated from one another (referring to, for example, Fig. 1).Further, every one deck of high-permeability material can be separated into fillet band, and it is separated to provide the adjacent ribbons of electricity isolation.Insulating barrier and the combined effect that material is divided into band are restrict eddy current significantly, and therefore limit hot generation.Secondly, these high-permeability materials are also easy to oxidized.In order to solve this misgivings, be known that and utilize the material that serves as vapor barrier 206 to cover on the main surface of the exposure of material.Further, high-permeability material may be relatively frangible and the impact that is subject to break and ruptures.Protectiveness outer (such as layer 206) can contribute to reduce the problem of breaking and producing in material.For example, the skin of PET can keep together the material breaking and reduce material fragment by the possibility fractureing.
Although compare the flux director of a lot of other traditional types, had obvious improvement, still needing to provide even larger control and can be by simply and the flux director of manufacturing at an easy rate to magnetic field.
Summary of the invention
The invention provides cover layer on a kind of opposite side with a plurality of alternating layers that are placed in high-permeability material and electrical insulating material and the lamination flux director of heat-conducting layer.In one embodiment, heat-conducting layer also conducts electricity.In one embodiment, heat-conducting layer is the thin layer of high heat conductivity metal.In one embodiment, metal can be aluminium.
In one embodiment, insulation material layer is placed between every one deck of high-permeability material layer and covers outmost high magnetic permeability layer.Insulating material can be selected to the electric insulation attribute that provides good, and limited thermal insulation is provided simultaneously.In one embodiment, insulating barrier can be formed by the thin layer of PETG (polyethylene terephthalate, " PET ").In one embodiment, insulating barrier can be a kind of as electrical insulating material and as the material that works for engaging the adhesive of adjacent layer of high-permeability material.For example, insulating barrier can be contact adhesive or heat-activated adhesive.In other embodiment, separated adhesive can be used to engage high-permeability material layer and insulation material layer.
In one embodiment, cover layer is formed by the material with good vapor barrier attribute, to reduce or eliminate the outermost oxidation of high magnetic permeability layer.Cover layer can be selected to intensity and the flexible attribute that provides good, even the in the situation that of breaking or rupture to become in one or more high magnetic permeability layer, contribute to lamination flux director to keep together.In one embodiment, cover layer is formed by the layer of PET or other polymer.
In one embodiment, each high magnetic permeability layer comprises a plurality of bands of high-permeability material, and it is separately isolated to produce electricity between adjacent ribbons.The width of band can be selected to the generation that prevents too much vortex flow when flux director is subject to expecting magnetic fields.As the temporary expedient of manufacturing, internal insulating layer can be cut or otherwise be divided into electricity isolation band together with high magnetic permeability layer.
In those embodiment that simultaneously also conduct electricity at heat-conducting layer, heat-conducting layer can be cut and be divided into electricity isolation band or otherwise be configured to reduce the amount of continuous material.This can reduce vortex flow and minimize the loss being associated in heat-conducting layer.
In one embodiment, lamination flux director can be coupled to radiator.For example, heat-conducting layer can be engaged to radiator or be engaged to the heat pipe that heat is transported to radiator.Heat-conducting layer can directly be joined to radiator or heat pipe, or electrical insulating material can be placed between them.In the middle of comprising, in the embodiment of electric insulation layer, insulating material can be selected to the thermal insulation that provides minimum.
In yet another aspect, the invention provides the method for the manufacture of lamination flux director, comprise following general step: a plurality of volumes that high-permeability material is provided; Heat Conduction Material volume is provided; Cladding material volume is provided; Between the adjacent layer of high-permeability material layer, apply jointing material, this jointing material can work as electrical insulating material; By high-permeability material with together with applied adhesive, be fed in one group of pressure roll to engage each layer to form presheaf casting die under pressure; Heat-conducting layer, presheaf casting die and cladding material are fed in one group of pressure roll to be bonded into final laminate under pressure, and final laminate are cut into the shape of expectation.In one embodiment, Heat Conduction Material is the thin layer volume of aluminium or other metals.
In one embodiment, every floor height magnetoconductivity material can comprise a plurality of between adjacent ribbons separately to produce the fillet band of the material of electricity isolation.In this embodiment, the method can comprise the steps: presheaf casting die to cut into the band of longitudinal extension; Separated adjacent ribbons to be so that electricity isolation to be provided at bar interband, and the separation of maintaining item interband during forming final laminate, make band in final laminate in electrically isolated from one.
In one embodiment, the method comprises the step of the high-permeability material of annealing.High-permeability material can be annealed the arbitrfary point in manufacture process in essence, such as before or after its coiling, and before or after material is cut into fillet band.In conjunction be not annealed damage bonding/embodiment of insulating material in, high-permeability material can be annealed after presheaf casting die is formed.In combination, be not annealed in the final insulating barrier of damage and the embodiment of heat-conducting layer, high-permeability material can be annealed after final laminate is formed.
In one embodiment, the method is included in the step that applies adhesive (or adhesive) between adjacent layer.For example, the method can comprise at least one in the match surface at every layer of place and applies the step of contact adhesive or heat-activated adhesive.Adhesive can be applied to material before material is formed rolling.Alternatively, adhesive can be applied at material material after batching out.For example, the method only can comprise that before material enters pressure roll at least one to match surface applies the step of adhesive.When using heat-activated adhesive, the method may further include to laminate and applies heat with the step of activated adhesive.Can pass through the one or more pressure rolls of heating, or carry out heating steps by external heat source.In certain embodiments, adhesive can not only engage the adjacent layer of high-permeability material but also work as electrical insulating material.
The invention provides a kind ofly can provide highly the simple and effective flux director of controlling to magnetic field, and improved heat management is also provided simultaneously.The alternately use of synusia of high-permeability material and electrical insulating material has reduced vortex flow, and has therefore reduced hot generation.Each high magnetic permeability layer is divided into band again and has also reduced vortex flow and heat generation.Outside heat-conducting layer provides a kind of for the structure from lamination flux director draw heat.When being directly or indirectly coupled to radiator or heat pipe, this heat-conducting layer can be provided for removing the active path of heat from lamination flux director.Even if cover layer contributes to, one or more the becoming of frangible high magnetic permeability layer ruptured or breaks sometimes, and lamination flux director is kept together.Cover layer also can provide protection bottom high magnetic permeability layer to avoid the vapor barrier of oxidation.Manufacture method of the present invention provides a kind of simple, cheap and high repeatable method for the manufacture of flux director.The use of material webs has reduced and material has been fed to the complexity that laminating apparatus is associated.Using by providing consistent laminate with simple and high reliability equipment of one or more groups pressure roll.
These and other object, advantage and feature of the present invention is by the description of the embodiment by reference to current and accompanying drawing and understood more fully and be familiar with.
Before in detail explaining embodiments of the invention, should be understood that, the invention is not restricted to the details of operation, or be not limited to according to following description set forth or accompanying drawing in details and the layout of structure of illustrated parts.The present invention can realize according to various other embodiment, and can be according to not having clearly disclosed alternative to put into practice or carry out at this.And, it should be understood that as used herein term or term are should be counted as restriction for purposes of illustration and not." comprise " and " comprising " with and the use intention of distortion be encompassed in listed thereafter project and equivalent thereof, and addition item and equivalent thereof.Further, in the description of various embodiment, can use and enumerate.Unless separately have clearly statement, the use of enumerating should not be interpreted as limiting the invention to any particular order or the quantity of parts.The use of enumerating is not appreciated that yet and can gets rid of outside scope of the present invention with the step of enumerating or the combined any additional step of parts or parts.
Accompanying drawing explanation
Fig. 1 is according to the end view of the lamination flux director of prior art.
Fig. 2 is according to the end view of lamination flux director of the present invention.
Fig. 3 shows according to the representational view of the manufacture of flux director of the present invention.
Fig. 4 shows the end view of the flux director that is coupled to radiator.
Fig. 5 shows the end view that is coupled to the flux director of radiator by heat pipe.
Fig. 6 is by the performance of lamination flux director of the prior art and the representational view comparing according to the performance of lamination flux director of the present invention.
Embodiment
Figure 2 illustrates lamination flux director according to an embodiment of the invention.Lamination flux director 10 generally includes cover layer 15 and the heat conduction skin 16 on the opposite side of layout of the alternating layer that is placed in high-permeability material 12a-d and electrical insulating material 14a-c.The quantity of alternating layer can change.Cover layer 15 can be the thin layer that lamination flux director can be kept together and provide the material of the vapor barrier of protecting bottom high-permeability material layer.Heat-conducting layer 16 can be also lamination flux director can be kept together and provide the vapor barrier of protection high-permeability material layer above, and the metal of heat flow path or the thin layer of other Heat Conduction Materials that are provided for shifting out from flux director heat energy.For example, heat-conducting layer can be directly or indirectly coupled to radiator 30 or the heat pipe 32 (referring to Fig. 4 and Fig. 5) that can extract heat energy.Heat-conducting layer 16 also can conduct electricity, and therefore allows heat-conducting layer 16 also as the shielding in magnetic field is worked.
The present invention is described in a kind of situation of lamination flux director, and this lamination flux director is arranged to for by the electronic equipment of magnetic field or electromagnetic field wireless charging.In this situation, lamination flux director is intended to help to control the magnetic flux being associated with the supply of wireless power.Yet the present invention is very suitable for other application of flowing for possibility desired control magnetic field.Directional terminology, such as " vertically ", " level ", " top ", " bottom ", " top ", " bottom ", " inside ", " upcountry ", " outside " and " outwards ", for helping based on describing the present invention in the orientation of the embodiment shown in diagram.The use of directional terminology should not be interpreted as limiting the invention to any one or more and specifically be orientated.The thickness that should also be noted that the various layers of lamination flux director 10 is exaggerated in the drawings so that open.
The lamination flux director 10 of Fig. 2 generally includes high magnetic permeability part 20 and thermal conduction portions 22.High magnetic permeability part 20 comprises a plurality of high-permeability material layer 12a-d by a plurality of electrical insulation material layer 14a-c separation.Additional electrical insulation material layer 14d can be placed between heat-conducting layer 16 and adjacent high-permeability material layer 12d.In the illustrated embodiment, have four high-permeability material layers, but the quantity of layer can be different from being applied to application on demand.For example, have in the situation in larger magnetic field, may expect to increase the quantity of layer; And have in the situation in less magnetic field, may expect to reduce the quantity of layer.
High-permeability material layer 12a-d can be by the soft magnetic material manufacturing in conjunction with " high-permeability material ".More specifically, high magnetic permeability layer can be by one or more material manufacturings that have relative permeability and surpass 100, have the representative value in the scope of 1000-70000+.For example, high-permeability material can be the type that is suitable for the amorphous metal, metal glass and the nanocrystal metal that use in the manufacture of high-performance flux director.A kind of suitable material be available from Vacuumschmelze GmbH & Co.KG, under trade (brand) name VITROPERM (such as VITROPERM800), comprise amorphous and soft magnetic material nanocrystal alloys.In the illustrated embodiment, every one deck of high-permeability material is all by identical material manufacturing and all have approximately identical thickness (0.0008 inch).Yet if necessary, the type of high-permeability material and thickness can be from layers to layer and different.
In the embodiment of Fig. 2, each high magnetic permeability layer 12a-d comprises a plurality of high-permeability material bands, and it is separately produced electricity isolation with the bar interband adjacent.For example, in the illustrated embodiment, the gross thickness of lamination flux director 10 is approximately 2.5 inches and has 20 bands of about 0.125 inch.The width of band can be selected to and when lamination flux director 10 is subject to expecting influence of magnetic field, prevents the generation of (with too much heat) of too much vortex flow, different from being applied to application but this width can depend on various factors.For example, when magnetic field hour, can use wider band, system can from lamination flux director 10, extract heat rapidly and/or system can sustain more heat.On the other hand, when magnetic field is larger, can use narrower band, system can not promptly extract heat and/or system can sustain less heat.Although in the illustrated embodiment high magnetic permeability layer 12a-d is divided into band, the present invention in some applications can utilize undivided high magnetic permeability layer 12a-d to realize.
As mentioned above, electric insulation layer 14a-c is placed between each high-permeability material layer 12a-d, so that electricity isolation to be provided between adjacent layer.The principle object of insulating barrier 14a-c is separated high magnetic permeability layer 12a-d and therefore reduces the vortex flow that may be generated by magnetic field in this embodiment.Insulating barrier 14a-c in fact can be by any electrical insulating material manufacturing.Yet, in the embodiment of Fig. 2, insulating barrier 14a-c by can either electricity isolation adjacent layer again can adhesive bond described in the material manufacturing of layer.For example, insulating barrier 14a-c engages adjacent layer and has been applied in adequate thickness to produce the contact adhesive of electricity isolation.In the illustrated embodiment, insulating barrier 14a-c is contact adhesive, and such as acrylic acid, it has the thickness of about 0.001 inch.As another example, insulating barrier 14a-c has sufficient intensity multilayer is kept together and have adequate thickness so that the heat-activated adhesive of electricity isolation to be provided.As another example, each insulating barrier 14a-c can be the polymeric layer of a kind of high-permeability material layer 12a-d that can bond adjacent when it is curing.Can also expect to use a kind of electrical insulating material only with limited thermal insulation attribute.In the situation that material has more high-termal conductivity, the lamination flux director 10 inner heat generating that can dissipate quickly.Alternatively, insulating barrier 14a-c can be by the material manufacturing that can not easily engage adjacent high-permeability material layer 12a-d.In this application, independent adhesive can be placed between high magnetic permeability layer 12a-d and insulating barrier 14a-c.For example, in such embodiment, insulating barrier 14a-c can be formed by the thin layer of PETG (" PET "), and various layer 12a-d and 14a-c can engage by contact adhesive or heat-activated adhesive (not shown).
As shown in Figure 2, can apply to the outer surface of high magnetic permeability layer 12d insulating barrier 14d.Insulating barrier 14d can be by the material manufacturing identical with insulating barrier 14a-c, but also can be as required by different material manufacturings.In this embodiment, insulating barrier 14d is by being selected to the material manufacturing of the outer surface of high magnetic permeability layer 12d and heat-conducting layer 16 electricity isolation.If heat-conducting layer 16 does not have good vapor barrier attribute, insulating barrier 14d can be by also having for reducing or eliminating the material manufacturing of good vapor barrier attribute of the oxidation of high magnetic permeability layer 12d.When thering is other insulating barriers 14a-c, insulating barrier 14d can by can either electricity isolation adjacent layer again can adhesive bond described in the material manufacturing of layer, or by the independent adhesive of needs, engaged the material manufacturing of described layer.For example, insulating barrier 14a-c engages adjacent layer and is applied in adequate thickness to produce electric contact adhesive of isolating between heat-conducting layer 16 and high magnetic permeability layer 12d, heat-conducting layer 16 can be bonded to heat-activated adhesive or the polymeric layer of high magnetic permeability layer 12d.In the illustrated embodiment, insulating barrier 14d is contact adhesive, and for example acrylic acid, has the thickness of about 0.001 inch.
Although do not illustrate, can apply to the outer surface of heat-conducting layer 16 insulating barrier so that the isolation of the electricity between heat-conducting layer 16 and radiator or heat pipe to be provided.For example, can apply to the outer surface of heat-conducting layer 16 thin layer of PET.
Referring again to Fig. 2, can apply to the outer surface of high magnetic permeability layer 12a cover layer 15.Even if cover layer 15 can be by being selected in the situation that the material manufacturing that the one or more fractures in vapor barrier and high magnetic permeability layer 12a-d is provided on high magnetic permeability layer 12a or breaks lamination flux director 10 is kept together.Cover layer 15 can be the vapor barrier that reduces or eliminates the oxidation of high magnetic permeability layer 12d.For example, cover layer 15 can be by PET, PVC, other similar flexibilities but the thin layer of firm polymer formed.The inner surface of cover layer 15 can apply with adhesive, all contact adhesives in this way of adhesive or heat-activated adhesive.
Although do not illustrate, can apply to the outer surface of heat-conducting layer 16 the second cover layer and think that lamination flux director 10 provides additional intensity and integrality.If this may be especially favourable in the situation that heat-conducting layer 16 comprises a plurality of separated band, as below described in the alternate embodiment.When heat-conducting layer 16 comprises separated band, the additional cover layer on the bottom of lamination flux director 10 can contribute to whole assembly to keep together, and also can contribute to provide protection high magnetic permeability layer to avoid the vapor barrier of oxidation.
Thermal conduction portions 22 generally includes thermal conductive material layer 16.As shown in Figure 2, in the illustrated embodiment by heat-conducting layer 16 layout adjacent with insulating barrier 14d.Heat-conducting layer 16 can be to have the high heat conductivity metal of enough thermal conductivities or the thin layer of other materials.In the illustrated embodiment, Heat Conduction Material has the thermal conductivity in the scope of 200-500W/ (M*K), but it can be any materials with the thermal conductivity that the thermal conductivity of the surrounding's material (such as the air in a lot of typical environment) than relevant environment is larger in essence.For example, in some applications, Heat Conduction Material can be a kind of thermal conductive polymer.The amount of the thermal conductivity of expectation can depend on various factors and apply difference from being applied to, such as the heat that depends on environment and generate in lamination flux director 10.For example, when generating less heat, may need less thermal conductivity, the electronic equipment that environment can extract rapidly heat and/or lamination flux director 10 is installed from heat-conducting layer can sustain relatively high heat.On the other hand, when flux director generates more heat transfer, may need larger thermal conductivity, environment can not promptly can sustain relatively low heat from heat-conducting layer extraction heat and/or relevant electronic equipment.In illustrated embodiment, heat-conducting layer is the thin layer of aluminium with the thickness of about 0.01 to 0.25 inch.This scope is only that thickness exemplary and heat-conducting layer in some applications can be thicker or thinner.In order to be beneficial to by method described below, manufacture lamination flux director 10, aluminium lamination can be enough thinly it to be provided with roll-good form allowing, but it is not strict essential.Aluminium is very suitable for this and specifically applies, because it has high thermal conductivity, good mechanical strength, is flexible and lightweight and is effective vapor barrier.Although aluminium can provide the best combination of characteristic for a lot of typical application, high heat conductance layer can be formed by other materials, all other metals or the other materials in this way with high heat conductance of other materials.
In the illustrated embodiment, heat-conducting layer 16 also conducts electricity.This allows heat-conducting layer 16 as providing the shielding of further control magnetic flux to work.For example, when conduction, vortex flow can be brought out in magnetic field in heat-conducting layer.In fact, this may reduce or eliminate through the passing through of the magnetic field of heat-conducting layer, and therefore in the environment on the opposite side of heat-conducting layer, has shielded magnetic field object.For example, Fig. 6 shows does not have the lamination of heat-conducting layer flux director 200 (left side) and the representativeness comparison of magnetic field M of lamination flux director 10 (right side) that comprises the heat-conducting layer 16 of conduction in prior art.In this represents, by lamination flux director 200 and 10 with the induced emission coil C placed adjacent of generation magnetic field M.As can be seen, the in the situation that of prior art lamination flux director 200, magnetic field M extends below the minimum end of flux director 200.Yet the in the situation that of lamination flux director 10, heat-conducting layer 16 is as preventing that magnetic field M from extending beyond the shielding of heat-conducting layer 16 and working.The improved magnetic property of lamination flux director is given the credit to the diamagnetic effect of the material 16 (for example aluminium or copper) of heat conduction and conduction.This diagram shows lamination flux director 10 and can be configured to, by being placed on lamination flux director 10 object below, comprise metal (for example steel) object, and M shields with magnetic field.Be also to be noted that lamination flux director 10 can be incorporated into from the remote equipment of radio source reception induced power.In such application, lamination flux director can be close to the receiving coil relative with transmitting coil and be placed.More specifically, lamination flux director 10 can be placed as cover layer 15 and heat-conducting layer 16 adjacent with receiving coil on opposite side.In such application, heat-conducting layer 16 can be used as shielding and works, and it contributes to hold the magnetic field of being launched by transmitter coil.Although the heat-conducting layer 16 in illustrated embodiment has good conductivity attribute, heat-conducting layer 16 can be by material (such as the thermal conductive polymer) manufacturing with low conductivity parameter.In the situation that the vortex flow that expectation restriction is produced by electric conducting material and the thermal loss being associated can realize this alternative.
At heat-conducting layer 16, conduct electricity but expect that in those application of the heat that restriction is generated by vortex flow, heat-conducting layer 16 can be cut into or be divided into the band that electricity is isolated, to reduce the amount of continuous material, this can reduce vortex flow and minimal thermal losses in heat-conducting layer.As discussed in conjunction with high magnetic permeability layer 12a-d above, in heat-conducting layer 16, the quantity of band can depend on various factors with width and different from being applied to application, still by be probably selected to enough narrow with at lamination flux director 10, expected influence of magnetic field time prevent the generation of (with too much heat) of too much vortex flow.
Lamination flux director 10 of the present invention can be coupled to other thermal management component to remove heat from system.For example, in the embodiment of Fig. 4, lamination flux director 10 is coupled to radiator 30, and in Fig. 5, lamination flux director 10 is coupled to heat pipe 32, itself then be coupled to radiator 30.Radiator 30 and heat pipe 32 can be any radiator or heat pipe in essence, comprise any traditional heat-dissipating device or the heat pipe of expectation heat dissipation can be provided in the packages limits of application.Heat-conducting layer 16 can directly be joined to radiator 30 or heat pipe 32, or electrical insulation material layer (not shown) can be placed between them.When directly being joined to radiator 30 or heat pipe 32, heat-conducting layer 16 can be engaged to radiator 30 or heat pipe 32 by heat-conductive bonding agent, all thermal conductive silicons in this way of heat-conductive bonding agent ketone adhesive, epobond epoxyn or transfering belt (transfer tape).In the middle of comprise in the embodiment of electric insulation layer, insulating material can be as above binder course 14a-d discuss insulating material in arbitrarily.
On the other hand, the invention provides a kind of method for the manufacture of lamination guider 10.In conjunction with Fig. 3, describe an embodiment of this method, Fig. 3 is for manufacture the schematically showing of manufacturing system of lamination guider 10 according to this manufacture method embodiment.The method generally includes following steps: a plurality of high-permeability material volumes are provided; Heat Conduction Material volume is provided, final insulating material volume is provided; Between the adjacent layer of high-permeability material layer, apply jointing material, above-mentioned jointing material can work as electrical insulating material; By high-permeability material with together with applied adhesive, be fed in one group of pressure roll to engage each layer to form presheaf casting die under pressure; Heat-conducting layer, presheaf casting die and final insulating material are fed in one group of pressure roll they are bonded into final laminate and the shape that final laminate is cut into expectation under pressure.In the illustrated embodiment, high-permeability material is a kind of amorphous and soft magnetic material nanocrystal alloys that comprises, it can obtain from Vacuumschmelze GmbH & Co.KG, under the trade (brand) name (such as VITROPERM800) of VITROPERM.Yet high magnetic permeability layer can be can be with other high-permeability materials of roll-good form supply.In the illustrated embodiment, Heat Conduction Material is aluminium thin layer volume, but as discussed above, can use other materials.
Referring now to Fig. 3, manufacturing system 100 is included as a plurality of high-permeability material volume 102a-d of layer 12a-d supply high-permeability material.During manufacture, four conveyer belts (web) 104a-d that pulls out high-permeability material from four volume 102a-d is to form four high magnetic permeability layer 12a-d.
In this embodiment, insulating barrier 14b-e is formed by the insulating material of high magnetic permeability layer 12a-d is bonding and electric insulation.For this reason, the manufacturing system 100 of this embodiment comprises the in-line arrangement applicator (inline applicator) 108 that is positioned at volume 102a-d downstream.This applicator 108 is configured to apply insulation/jointing material to the suitable surface of conveyer belt 104a-d.More specifically, in this embodiment, when conveyer belt is delivered to pressure roll 106a-b (discussing below) from volume 102a-d, applicator 108 applies insulation/bonding material layer to the lower surface of conveyer belt 104a-d.Insulation/jointing material can alternatively be applied to the upper surface of conveyer belt 104b-d, or is applied to the lower surface of conveyer belt 104a-d and the upper surface of conveyer belt 104a-d.Applicator 108 can comprise sprinkler, roller or can apply to conveyer belt 104a-d other mechanisms of insulating material.In this embodiment, insulating material can be that contact adhesive, heat-activated adhesive maybe can be by adjacent conveyer belt 104a-d insulation and the polymer being bonded together.In some applications, may be desirably in pressure roll 106a-b and to the basal surface of conveyer belt 104d, apply insulating material afterwards.This insulating material can be used to form insulating barrier 14d heat-conducting layer 16 is engaged with high magnetic permeability layer 12d and electricity isolation.Insulating material for this layer can be identical from the material that is used to form insulating barrier 14a-c or different.
In this embodiment, next high magnetic permeability conveyer belt 104a-d is bonded together to form presheaf casting die 110 with the insulating material applying.Conveyer belt 104a-d and insulating material can engage by pressure and possible heat.As shown in Figure 3, the conveyer belt 104a-d of coating is fed in a pair of pressure roll 106a-b.Pressure roll 106a-b is configured to apply correct amount of pressure, and possible heat, so that insulation/jointing material is bonded into presheaf casting die 110 by conveyer belt 104a-d.In the application that applies heat, can or independent thermal source be attached in system one in roller 106a-b or both heating.For example, thermolamp or pharoid can be placed on to pressure roll 106a-b before to apply correct heat to activate or otherwise to help insulating material adhesive bond adjacent layer and to form insulating barrier 14a-d.In some applications, may expect provides inviscid coating to base pressure roller 106b, to prevent that insulating material is accumulated on base pressure roller 106b.
In the illustrated embodiment, presheaf casting die 110 is divided into the fillet band that comprises a plurality of longitudinal extensions, and these fillet bands separately produce electricity isolation with the bar interband adjacent.In this embodiment, presheaf casting die 110 is cut into band and these bands and is being arranged in the in-line arrangement cutting platform in pressure roll 106a-b downstream (inline slitting station) 112 by separately.Yet high-permeability material layer and possible insulating barrier can be divided into band at other times.For example, high-permeability material volume can be split by pre-cutting or they before conveyer belt 104a-b is fed in pressure roll 106a-b in in-line arrangement platform.Band keeps separately during forming final laminate 120, make band in final laminate 120 in electrically isolated from one.
In the illustrated embodiment, the method comprises the step of the high-permeability material of annealing.High-permeability material can be annealed the arbitrfary point in manufacture process in essence, before or after being wound rolling at it, and is annealed before or after material is cut into fillet band.Combine be not annealed damage bonding/embodiment of insulating material in, high-permeability material can be annealed after presheaf casting die is formed.Be not annealed in the cover layer of damage and the embodiment of heat-conducting layer combining, high-permeability material can be annealed after final laminate is formed.In the illustrated embodiment, high-permeability material was annealed before it is wound rolling 102a-d.In expectation, anneal later in the application of high-permeability material, in-line arrangement anneal station can be incorporated in manufacturing system 100.For example, anneal station can be positioned at the downstream of rolling up 102a-d and the upstream that is positioned at applicator 108.
Presheaf casting die 110 be cut into band and separated after, cover layer 15 is applied to the top of presheaf casting die 110 and the bottom that heat-conducting layer 16 is applied to presheaf casting die 110.In this embodiment, cover layer 15 is applied simultaneously presheaf casting die 110 with heat-conducting layer 16.Referring now to Fig. 3, cover layer 15 is provided to roll up 114 form, and this volume 114 is placed with and allows to pull out cover layer 15 and be fixed to presheaf casting die 110 by second group of pressure roll 116a-b from this volume.For example, the cover layer 15 of illustrated embodiment can be PET volume.In this embodiment, cover layer 15 is provided for engaging in advance the adhesive phase of cover layer 15 and the upper surface of presheaf casting die.For example, contact adhesive or heat-activated adhesive can be applied to the basal surface of PET before PET is wound rolling 114.Adhesive can be alternatively applied to cover layer 15 from rolling up 114 after pulling out by material.For example, adhesive applicator (not shown) can be placed between volume the 114 and second pressure roll 116a-b.Similarly, heat-conducting layer 16 is provided to roll up 118 form.Volume 118 can be placed with on the basal surface that Heat Conduction Material is fed to presheaf casting die 110 before second roller 116a-b.Insulating barrier 14d can be used to heat-conducting layer 16 to be fixed to presheaf casting die 110.For example, in insulating barrier 14d, required amount of pressure or the heat of activated adhesive can be supplied by second roller 116a-b or at second roller 116a-b place.Although cover layer 15 and heat-conducting layer 16 are by applying with second group of pressure roll 116a-b in this embodiment, one or the two can be alternatively by applying with the first pressure roll 106a-b.For example, in alternate embodiment, high magnetic permeability layer 12a-d can be separated into band, and cover layer 15 can be fed in the assembly of conveyer belt by heat-conducting layer 16 before the first pressure roll 106a-b.The in the situation that of this alternate embodiment, single group pressure roll can combine all layers in order to form the continuous conveyor of final laminate 120 simultaneously.
After each layer is engaged by second roller 116a-b, conveyer belt 104a-d, insulating barrier 14a-d, cover layer 15 and heat-conducting layer 16 have formed the continuous conveyor of final laminate 120 jointly.Next can cut the continuous conveyor of this final laminate 120 to form final lamination flux director 10.In the illustrated embodiment, the continuous conveyor of final laminate 120 is cut into lamination flux director 10 at cutting bed 122 places.Cutting bed 122 cuts continuous conveyor to be divided into the segregation section corresponding with the desired size of lamination guider 10 in a lateral direction by conveyer belt.If continuous conveyor is wider than the desired size of lamination guider 10, cutting bed 122 also can be configured to carry out longitudinal cutting.For example, can be configured to be that the twice of lamination guider 10 desired width is wide to the continuous conveyor of final laminate 120.In such application, except transverse cuts, cutting bed can also be carried out the longitudinal cutting into two of conveyer belt 120 horizontal partition.Cutting bed 122 can comprise in essence can cut into the conveyer belt of final laminate 120 any equipment of each lamination flux director 10.For example, cutting bed 122 can comprise traditional bicker (die cutting machine).Alternatively, cutting step can be carried out by adding cutting blade to second group of pressure roll 116a-b.
In some applications, may expect by heat-conducting layer 16 separated components from band.Although do not illustrate, this can complete in heat-conducting layer 16 being incorporated into manufacture process before first group of pressure roll 106a-b.In such application, heat-conducting layer 16 will be included among presheaf casting die 110 and in-line arrangement cutting platform 112 will cut with separated the remainder of heat-conducting layer 16 and presheaf casting die 110.
In some applications, may be desirably on the outer surface of heat-conducting layer 16 and add bottom cover layer (not shown).This may be especially useful when heat-conducting layer 16 has been divided into separated band.In such application, bottom cover layer can cooperate lamination flux director 10 is kept together with top cover layer.Can before second group of pressure roll 116a-b, by introducing bottom cover layer, add bottom cover layer (not shown) to final laminate 120.For example, bottom cover layer material webs (not shown) can be placed with and allow before material enters second group of pressure roll 116a-b, and bottom cladding material is moved in the position of the outer surface of heat-conducting layer 16.This joins bottom cover layer permission to final laminate 120 in by second group of pressure roll 116a-b.If necessary, top cover layer 16 and bottom cover layer (not shown) can be designed to be of a size of and extend beyond intermediate layer, make top cover layer 16 and the bottom cover layer can be being joined together at least partly along their peripheries.In the application of expectation whole peripheral engage top cover layer and bottom cover layer around them, top cover layer and bottom cover layer can be applied at the continuous conveyor of final laminate 120 after cutting bed 118 places are cut.
Described above is the description of current embodiment of the present invention.In the situation that not deviating from as spirit of the present invention defined in the appended claims and wider aspect, can make various changes and modification, spirit of the present invention and wider aspect make an explanation the principle according to having comprised the Patent Law of doctrine of equivalents.The disclosure presents for illustration purposes, and should not be interpreted as the exhaustive of all embodiment of the present invention or the scope of claim is restricted to concrete element illustrated in conjunction with these embodiment or that describe.For example, and unrestricted, arbitrarily indivedual elements of described invention can be by approximation function being provided substantially or otherwise providing the alternative elements of proper handling to be replaced.For example, this comprises known alternative elements at present, such as being current those the known elements of those skilled in the art; And the alternative elements of developing in the future, such as those skilled in the art, when developing, may be identified as those elements of alternative.Further, the disclosed embodiments comprise a plurality of features of unanimously being described and benefit set may being provided jointly.Except the degree of clearly setting forth in addition in issued claim, the present invention is not only limited to those embodiment of the benefit that comprises all these features or all statements are provided.With singulative, any of claim element quoted, for example, use article " (a, an) ", " being somebody's turn to do (the) " or " described (said) ", not being interpreted as this element limits is odd number.

Claims (24)

1. a lamination flux director, comprising:
A plurality of high-permeability material layers;
A plurality of electrical insulation material layers, arrange described high-permeability material layer and described insulation material layer in the mode of alternating layer; And
Heat-conducting layer with the adjacent layout of described alternating layer.
2. flux director as claimed in claim 1, every one deck of wherein said a plurality of high-permeability material layers comprises the bands of a plurality of electricity isolation.
3. flux director as claimed in claim 2, wherein said heat-conducting layer is metal level.
4. flux director as claimed in claim 2, wherein said heat-conducting layer is aluminium lamination.
5. flux director as claimed in claim 4, further comprises the cover layer adjacent with described alternating layer, wherein described cover layer and described heat-conducting layer is placed on the opposite side of described alternating layer, and described cover layer provides vapor barrier.
6. flux director as claimed in claim 5, every one deck of wherein said a plurality of insulation material layers is adhesive.
7. flux director as claimed in claim 6, further comprises the electrical insulation material layer being placed between described alternating layer and described heat-conducting layer.
8. an assembly, comprising:
Induction coil, it is configured to generate or receive magnetic field; And
Lamination flux director, its layout adjacent with described induction coil, described lamination flux director has:
The magnetic permeability part that comprises the alternating layer of high-permeability material and electrical insulating material; And
Be adjacent to the heat-conducting layer that the described magnetic permeability relative with described induction coil partly arranged.
9. assembly as claimed in claim 8, wherein said heat-conducting layer is metal level.
10. assembly as claimed in claim 8, wherein said heat-conducting layer is aluminium lamination.
11. assemblies as claimed in claim 9, further comprise the cover layer adjacent with described magnetic permeability part, wherein described cover layer and described heat-conducting layer are placed on the opposite side of described magnetic permeability part.
12. assemblies as claimed in claim 11, the every one deck in wherein said a plurality of electrical insulation material layers is the adhesive of a pair of described high-permeability material layer that bonding is adjacent.
13. assemblies as claimed in claim 12, further comprise the electrical insulation material layer being placed between described magnetic permeability part and described heat-conducting layer.
14. assemblies as claimed in claim 8, the every one deck in wherein said high-permeability material layer comprises the band of a plurality of electricity isolation.
15. assemblies as claimed in claim 14, wherein said heat-conducting layer comprises the band of a plurality of electricity isolation.
16. 1 kinds of methods of manufacturing lamination flux director, comprise the steps:
A plurality of high-permeability material volumes are provided, and described in each, volume comprises the continuous conveyer belt of described high-permeability material;
Between continuous conveyer belt, provide electric insulation layer;
Described conveyer belt and insulating barrier are fed in pressure roll to form presheaf casting die;
Continuous Heat Conduction Material volume is provided;
Continuous cladding material volume is provided; And
Described Heat Conduction Material, presheaf casting die and cladding material are fed in pressure roll to form final laminate.
17. methods as claimed in claim 16, further comprise the step that described presheaf casting die is divided into the band of electricity isolation.
18. methods as claimed in claim 17, wherein said segmentation step comprises the steps: presheaf casting die is cut into a plurality of bands and the separated enough distances of described band are isolated to provide electric between adjacent band.
19. methods as claimed in claim 18, wherein said heat-conducting layer is metal.
20. methods as claimed in claim 18, wherein said heat-conducting layer is aluminium.
21. methods as claimed in claim 16, wherein said adjacent continuous conveyor is to having the surface of a pair of coupling; And
The wherein said step that insulating barrier is provided between continuous conveyor comprises electric insulation adhesive is applied to at least one in every pair of match surface.
22. methods as claimed in claim 16, the wherein said step of insulating barrier that provides between continuous conveyer belt comprises the steps:
A plurality of insulating material volumes are provided, and each insulating material volume comprises the continuous conveyer belt of electrical insulating material;
Described described conveyer belt and insulating barrier are fed to pressure roll in before forming the step of presheaf casting die, between every pair of conveyor belt of high-permeability material, place insulation material layer.
23. methods as claimed in claim 22, wherein each adjacent a pair of high magnetic permeability continuous conveyor and described insulating barrier continuous conveyor have the surface of a pair of coupling; And
The wherein said step that insulating barrier is provided comprises adhesive is applied to at least one the step in every pair of match surface.
24. methods as claimed in claim 16, further comprise the step that final laminate is cut into lamination flux director.
CN201310145865.2A 2012-10-02 2013-03-14 Magnetic flux guide component Pending CN103714938A (en)

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