TW201415501A - Magnetic flux guide component - Google Patents

Abstract

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. 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

Flux guiding member

The present invention is generally directed to magnetic flux steering and methods of making magnetic flux guidance.

Magnetic flux guidance (sometimes referred to as flux concentrators, flux concentrators, flux enhancers, flux redirectors, flux controllers, flux reflectors, or other names) is well known and has been known It is used in applications to control the flow of magnetic fields, such as, for example, inductive heating and inductive power transmitter applications. Magnetic flux guidance generally assists in controlling the flow of magnetic fields by providing a high permeability flow path. By providing a high permeability flow path, a magnetic flux guide provides a path of least resistance and can effectively introduce more magnetic fields. This enhances the magnetic field in certain areas and helps increase power efficiency. Without a magnetic flux guide, the magnetic field is more likely to scatter and interfere with any conductive surrounding objects. In some cases, the flux mask can be a type of flux concentrator.

As mentioned above, the magnetic flux guiding is usually made of a material having a relatively high magnetic permeability. There are many types of high permeability materials that can be used to form magnetic flux guides. For example, soft magnetic materials, such as, for example, ferrite magnets, are often used to make magnetic flux guides. Ferrite magnet flux concentrators are very compact constructions, typically made by mixing iron oxide with an oxide or carbonate of one or more metals such as, for example, nickel, zinc or magnesium. The main disadvantage of ferrite magnet flux concentrators is that they tend to be fragile and prone to distortion when they are made into a thin profile. Typical ferrite magnet It also has a low saturation flux density, so it is easy to become saturated and it is no longer easier to pass the magnetic field than other air fields. This property may not be popular in some applications.

Another soft magnetic material that is sometimes used to make magnetic flux concentrators is magnetic dielectric material (MDM). These materials are made of a soft magnetic material as well as a dielectric material that acts as a binder and an insulator for each particle. Magnetic material flux concentrators can be divided into two categories: plastic and hard. The moldable magnetic dielectric material is like putty and is molded to conform to the shape of the coil. The hard magnetic dielectric material is produced by pressing a metal powder and a binder and then performing heat treatment. The characteristics of a magnetically permeable material flux concentrator will vary with the ratio of binder used. Typically, the less the binder, the higher the magnetic permeability. However, in conventional configurations, less binder is equivalent to more metal to metal contact, so more eddy currents are formed when using the flux concentrator. Although the MDM flux concentrator can be made into a sheet profile, it is quite difficult to fabricate a magnetic material flux concentrator with the desired magnetic and thermal properties, since changing the percentage of binder can have a competing effect.

While the soft magnetic materials discussed above provide higher magnetic permeability than ambient air and are generally effective magnetic flux guidance, materials with higher magnetic permeability may be more efficient in many types of applications. For example, an alternative soft magnetic material has a "high magnetic permeability material" (ie, a relative magnetic permeability exceeding 100, typically having a value in the range of 1000 to 70,000 or more), such as various types of amorphous metals, Metallic glass and nanocrystalline metal are suitable for high performance magnetic flux guidance. While these materials can provide much higher magnetic permeability than other soft magnetic materials, they are subject to certain potential drawbacks. First, they are generally extremely conductive, which can result in eddy currents and unwanted heating in the material. Lamination has been developed to address heating concerns Magnetic flux guidance. A typical laminated magnetic flux guide (200) includes a plurality of thin layers of high magnetic permeability material (202) separated from one another by a thin insulating layer (204) (see, for example, the first figure). Further, the high permeability materials of the various layers can be separated into narrow strips to provide adjacent strips that are electrically separated independently. The combination of the insulating layer and the division of the material into strips can significantly limit the eddy current and thus the heat production. Second, these high permeability materials are also susceptible to oxidation. To address this concern, it is known that the major surface that exposes the material to the outside is covered by a material as a wet oxygen barrier (206). Further, high permeability materials can be relatively fragile and prone to cracking or breaking. A protective outer layer, such as layering (206), can help reduce problems caused by cracks in the material. For example, the outer layer of PET can hold the ruptured material together and reduce the risk of material debris getting detached.

While there is a significant improvement over other conventional types of magnetic flux guidance, there is a need for magnetic flux guidance to provide better control of the magnetic field and to be simple and inexpensive to manufacture.

The present invention provides a laminated magnetic flux guide having a cover layer and a heat conducting layer disposed on opposite sides of a plurality of alternating layers of high permeability material and layers of electrically insulating material. In a specific embodiment, the thermally conductive layer can also be electrically conductive. In one embodiment, the thermally conductive layer is a thin layer of high thermal conductivity metal. In a specific embodiment, the metal can be aluminum.

In one embodiment, a layer of insulating material is placed between each of the high permeability layers and above the outermost high permeability layer. The insulating material can be selected to provide good electrical insulation properties while providing limited thermal insulation. In one embodiment, the insulating layer is formed from a thin layer of polyethylene terephthalate (PET). In a specific embodiment, the insulating layers may be a material It is used as an insulating material and acts as an adhesive for bonding two adjacent layers of high magnetic permeability material. For example, the insulating layers can be a pressure sensitive adhesive or a heat activated adhesive. In another embodiment, a separate adhesive can be used to bond the layer of high magnetic permeability material to the layer of insulating material.

In a specific embodiment, the cover layer is formed from a material that has good moisture barrier properties to reduce or eliminate oxidation of the outermost layer of high permeability layer. The cover layer can be selected to provide good strength and deflection characteristics to assist in guiding the laminated magnetic flux guides together even if one or more of the high permeability layers are broken or broken. In a specific embodiment, the cover layer is formed from a layer of PET or other polymer.

In one embodiment, each of the high magnetic permeability layers includes a plurality of strips of high magnetic permeability material spaced apart to cause electrical isolation between adjacent strips. The width of each strip can be selected to avoid excessive eddy currents when the magnetic flux guide is subjected to the desired magnetic field. As a workaround at the time of manufacture, the inner insulating layer can be cut or otherwise divided into electrically isolated strips along with the high permeability layer.

In these embodiments where the thermally conductive layer is electrically conductive, the thermally conductive layer can be cut and separated into electrically isolated strips or otherwise configured to reduce the amount of continuous metal. This reduces eddy currents and minimizes losses associated with the thermal conduction layer.

In a specific embodiment, the laminated magnetic flux guide can be coupled to a heat sink. For example, the heat conductive layer can be bonded to a heat sink or bonded to a heat pipe to tropic to a heat sink. The heat conductive layer can be bonded directly to the heat sink or heat pipe, or a layer of electrical barrier material can be placed between the two. In a specific embodiment including an intermediate electrically insulating layer, the insulating material can be selected to provide minimal thermal insulation.

In another aspect, the present invention provides a method for fabricating a laminated magnetic permeability, The steps are generally as follows: providing a plurality of high permeability materials; providing a roll of thermally conductive material to provide a roll of cladding material; applying an adhesive material between adjacent layers of high permeability material, the bonding material Capable of functioning as a heat insulating material; feeding a high magnetic permeability material and an applied adhesive to a set of press rolls to combine different layers under pressure to form a pre-pressed layer; heat transfer layer, preloading The plies and cladding material are fed into a set of press rolls to combine them under pressure into a final laminate and to cut the final laminate into the desired shape. In one embodiment, the thermally conductive material is a thin layer of aluminum or other metal.

In one embodiment, the layers of high permeability material may include a plurality of such elongated strips of material spaced apart to cause electrical isolation between adjacent strips. In such a particular embodiment, the method can include the steps of: cutting the pre-laminated sheet into longitudinally extending strips; separating the adjacent strips to provide electrical isolation between the strips and forming The separation between the strips is maintained during the final laminate so that the strips are electrically isolated from one another in the final laminate.

In a specific embodiment, the method includes annealing the step of the high permeability material. The high permeability material can be substantially annealed at any point during its manufacture, such as, for example, before or after being rolled into a roll, and before or after being cut into narrow strips. In a specific embodiment of an adhesive/isolation material that is not damaged by the annealing process, the high permeability material can be annealed prior to formation of the pre-compression lamination. In a specific embodiment where the final insulating layer is present and the thermally conductive layer is not damaged by the annealing process, the high magnetic permeability material can be annealed after the final laminate is formed.

In a specific embodiment, the method includes the step of applying an adhesive (gelling agent) between adjacent layers. For example, the method can include the step of applying a pressure sensitive adhesive or a heat activated adhesive to at least one corresponding face of each layer. The adhesive can be formed into a roll in a material The front is applied to the material. Alternatively, the adhesive can be applied after it has been removed from the drum. For example, the method can include the step of applying an adhesive to at least one of the opposing faces just prior to the material entering the press roll. If a heat activated adhesive is used, the method can further include the step of applying heat to the laminate to activate the adhesive. This heating step can be carried out by heating one or more press rolls or by an external heat source. In one embodiment, the adhesive can simultaneously bond adjacent high permeability materials and function as the same electrically insulating material.

The present invention provides a simple and effective magnetic flux guide that provides a high degree of control over the magnetic field while also providing improved thermal management. The use of alternating high permeability materials and stratification of electrically insulating materials reduces eddy currents and thus reduces heat generation. By dividing each high permeability layer into strips, eddy current and heat generation are also reduced. An outer thermally conductive layer provides a configuration for drawing heat from the laminated magnetic flux guide. When thermally or directly coupled to a heat sink or heat pipe, the heat conductive layer can provide an effective means for guiding heat away from the laminated magnetic flux. The cladding assists in guiding the laminated magnetic flux guides together even if one or more of the sometimes fragile high permeability layers are broken or cracked. The coating also provides a vapor barrier that protects the underlying high permeability layer from oxidation. The method of manufacture of the present invention provides a simple, inexpensive and highly reproducible method for making a magnetic flux guide. The use of a rolled material reduces the complexity associated with supplying the material to the laminating apparatus. Uniform lamination is provided by a simple and highly reliable device using one or more sets of press rolls.

These and other objects, advantages and features of the present invention will become more fully understood and appreciated from the <

Before the detailed description of the specific embodiments of the present invention, it is understood that the invention is not limited to the details of the details The present invention may be embodied in various other specific embodiments and may not be disclosed herein. An alternative method is implemented or achieved. Moreover, it is conceivable that the words and terms used herein are for the purpose of description and should not be considered as limiting. The use of "including" and "comprising" and its mutated usage are intended to encompass the items listed above and their equivalents, as well as additional items equivalent thereto. Further, the numbering can be used in the description of different specific embodiments. The use of numbers should not be construed as limiting the invention to any particular order of components or the number of components, unless otherwise indicated. The use of numbers is also not to be taken as limiting any additional steps or components that may be combined or combined with the numbered steps or components.

M‧‧‧ magnetic field

C‧‧‧ coil

10‧‧‧ laminated magnetic flux guidance

12a-d‧‧‧High magnetic permeability material

14a-d‧‧‧Electrical insulation materials

15‧‧‧ Coverage

16‧‧‧heat conduction layer

20‧‧‧High magnetic permeability

22‧‧‧Conducting part

30‧‧‧ radiator

32‧‧‧heat pipe

100‧‧‧ Manufacturing System

102a-d‧‧‧Volume

104a-d‧‧‧

106a-b‧‧‧pressure roller

108‧‧‧Applicator

110‧‧‧Precast laminate

114‧‧‧roll

116a-b‧‧‧pressure roller

118‧‧‧roll

120‧‧‧Final laminate

122‧‧‧Cutting station

200‧‧‧Magnetic flux guidance

202‧‧‧High magnetic permeability material

204‧‧‧Electrical insulation

206‧‧‧Moisture barrier

The first figure is a side view of a laminated magnetic flux guide according to the prior art.

The second drawing is a side view of a laminated magnetic flux guide in accordance with the present invention.

The third figure is a representative diagram of a magnetic flux guide in accordance with the present invention.

The fourth figure is a side view of the magnetic flux guide coupled to a heat sink.

The fifth figure is a side view of the magnetic flux guide coupled to a heat sink via a heat pipe.

The sixth figure is a schematic comparison of the performance of a prior art laminated magnetic flux guide and the laminated magnetic flux guide of the present invention.

Figure 2 shows a laminated magnetic flux guide in accordance with an embodiment of the present invention. The laminated magnetic flux guide (10) generally includes a cover layer (15) and a thermally conductive outer layer (16) placed on top of the layers of high magnetic permeability material (12a-d) and electrically insulating material (14a-c). The opposite sides of the configuration. The number of overlapping times can vary. The cover layer (15) may be a thin layer of material that is capable of guiding the laminated magnetic flux together and providing a high permeability layer beneath the moisture barrier. Heat conduction layer (16) It may be a thin layer of metal or other thermally conductive material that also guides the laminated magnetic flux together and provides a moisture barrier to protect the overlapping layers of high permeability material and provides a heat flow path for the thermal energy The magnetic flux guide is removed. For example, the thermally conductive layer can be coupled directly or indirectly to a heat sink (30) or to a heat pipe (32) capable of drawing thermal energy (see fourth and fifth figures). The heat conducting layer (16) can also be electrically conductive, thus allowing the heat conducting layer (16) to also function as a magnetic field mask.

The present invention is described in terms of a laminated magnetic flux guide for its use, which is configured to be used in conjunction with an electronic device that is wirelessly charged via a magnetic or electromagnetic field. In this context, a laminated magnetic flux guide is used to assist in controlling the magnetic flux associated with the wireless power supply. However, the invention is well suited for use in other applications where it may be desirable to control the flow of a magnetic field. Directional terms such as "vertical", "horizontal", "above", "below", "above", "below", "internal", "inward", "outside", "outward", It is intended to assist the description of the invention and is in accordance with the orientation of the specific embodiments illustrated in the drawings. The use of directional terms is not to be construed as limiting the invention to any particular orientation. It should also be noted that the different levels of thickness of the laminated magnetic flux guide (10) in the illustration are exaggerated to facilitate discussion.

The laminated magnetic flux guide (10) of the second figure generally includes a highly magnetically conductive portion (20) and a thermally conductive portion (22). The highly magnetically permeable portion (20) includes a plurality of layers of high permeability material (12a-d) separated by a plurality of layers of electrically insulating material (14a-c). An additional layer of electrically insulating material (14d) can be placed between the thermally conductive layer (16) and the adjacent layer of high permeability material (12d). In the particular embodiment depicted, there are four layers of high permeability material, but the number of levels can vary from application to application depending on the application. For example, with a larger magnetic field, it may be desirable to increase the number of levels, with a smaller magnetic field, and it may be desirable to reduce the number of levels.

The high magnetic permeability material layer (12a-d) may be made of a soft magnetic material having a "high magnetic permeability material". More specifically, the high magnetic permeability material may be made of one or more materials having a relative magnetic permeability of more than 100, and the value is in the range of 1000 to 70,000 or more. For example, the high magnetic permeability material can be an amorphous metal, metallic glass, and nanocrystalline metal suitable for use in the manufacture of high performance magnetic flux guidance. A suitable material is a soft magnetic material comprising an amorphous and nanocrystalline alloy available from Vacuumschmelze GmbH & Co. KG under the trade name VITROPERM, such as, for example, VITROPERM 800. In the specific embodiment 1 depicted, each layer of high magnetic permeability material is made of the same material and is about the same thickness (0.0008 Å). However, the type and thickness of the high permeability material may vary from layer to layer as desired.

In the specific embodiment of the second figure, each of the high magnetic permeability layers (12a-d) includes a plurality of strips of high magnetic permeability material spaced apart to cause electrical isolation between adjacent strips. For example, in the specific embodiment 1, the laminated magnetic flux guide (10) has a total thickness of about 2.5 angstroms and about 20 strips of about 0.125 angstroms. The width of the strip can be selected to avoid excessive eddy currents (and excessive heat) when the laminated magnetic flux guide (10) is subjected to the desired magnetic field, but the width can vary depending on various factors depending on the application. . For example, if the magnetic field is small, the system can quickly absorb heat from the laminated magnetic flux guide (10), and/or the system can tolerate higher heat, a wider strip can be used. On the other hand, when the magnetic field is large, the system does not absorb heat so quickly, and/or the system can tolerate less heat, narrower strips can be used. Although the high permeability layer (12a-d) is depicted as a growth strip in the specific embodiment, the invention may be practiced in some applications without the undivided high permeability layer (12a-d).

As noted above, electrically insulating layers (14a-c) are placed between the layers of high permeability material (12a-d) to provide electrical isolation between adjacent layers. The main body of the insulating layer (14a-c) in this embodiment The purpose is to separate the high permeability layers (12a-d) and thus reduce the eddy currents that may be generated by the magnetic field. The insulating layer (14a-c) can be made substantially of any electrically insulating material. However, in the specific embodiment of the second figure, the insulating layers (14a-c) are made of a material that is capable of electrically isolating adjacent layers and adhesively bonding the layers. For example, the insulating material (14a-c) can be a pressure sensitive adhesive that bonds adjacent layers and applies sufficient thickness to cause electrical isolation. In the particular embodiment depicted, the insulating layer (14a-c) is a pressure sensitive adhesive such as, for example, acrylic, having a thickness of about 0.001 Å. In another example, the insulating layer (14a-c) can be a heat activated adhesive having sufficient strength to hold the layers together and at a sufficient thickness to provide electrical isolation. In still another example, each of the insulating layers (14a-c) may be a layer of polymer capable of bonding adjacent high magnetic permeability materials (12a-d) when cured. It may also be desirable to use an electrically insulating material that has only limited thermal insulation properties. For materials with greater thermal conductivity, laminated magnetic flux guidance (10) may be able to dissipate internally generated heat more quickly. Alternatively, the insulating layers (14a-c) may be made of a material that does not readily bond adjacent layers of high magnetic permeability material (12a-d). In such an application, an additional separate adhesive can be placed between the layers of high permeability layer (12a-d) and the layer of insulating layer (14a-c). For example, in such embodiments, the insulating layers (14a-c) may be formed from a thin layer of polyethylene terephthalate (PET) with different layers (12a-d) and (14a-c) It can be combined by a pressure sensitive adhesive or a heat activated adhesive (not shown).

As shown in the second figure, an insulating layer (14d) may be applied to the outer surface of the magnetic permeability layer (12d). The insulating layer (14d) may be made of the same material as the insulating layers (14a-c), but may be desirably made of different materials. In this embodiment, the insulating layer (14d) is made of a material selected to electrically isolate the high magnetic permeability layer (12d) from the outer surface of the thermally conductive layer (16). If the heat conducting layer (16) does not have good moisture barrier properties, the insulating layer (14d) may be made of a material that also has a good moisture barrier to reduce or eliminate oxidation of the high permeability layer (12d). Such as other insulation layers (14a-c), absolutely The edge layer (14d) may be made of a material capable of electrically isolating adjacent layers and adhesively bonding the layers, or by a material that requires an additional adhesive to bond the layers. For example, the insulating layer (14a-c) may be a pressure sensitive adhesive that bonds adjacent layers together and applies sufficient thickness to create electrical isolation between the thermally conductive layer (16) and the high permeability layer (12d). A heat-enabled adhesive or a layer of polymer is capable of bonding the thermally conductive layer (16) to the high permeability layer (12d). In the particular embodiment depicted, the insulating layer (14d) is a pressure sensitive adhesive such as, for example, acrylic, having a thickness of about 0.001 Å.

Although not shown, an insulating layer can be applied to the outer surface of the thermally conductive layer (16) to provide electrical isolation between the thermally conductive layer (16) and the heat sink or heat pipe. For example, a thin layer of PET can be applied to the outer surface of the thermally conductive layer (16).

Referring to the second figure, a cover layer (15) may be applied to the outer surface of the high magnetic permeability layer (12a). The cover layer (15) may be made of a material selected to provide a moisture barrier to coat the high permeability layer (12a) and to hold the laminated magnetic flux guides (10) together, even if one or more high The magnetic permeability layer (12a-d) is broken or cracked. The cover layer (15) may be a moisture barrier that reduces or eliminates oxidation of the high permeability layer (12d). For example, the cover layer (15) may be formed from a thin layer of PET, PVC or other similar flexible but tough polymer. The inner surface of the cover layer (15) may be coated with an adhesive such as, for example, a pressure sensitive adhesive or a heat activated adhesive.

Although not shown, a second cover layer can be applied to the outer surface of the thermally conductive layer (16) to provide additional strength and integrity to the laminated magnetic flux guide (10). It would be particularly advantageous if the thermally conductive layer (16) included a plurality of separate strips as described in the alternative embodiments that follow. If the thermally conductive layer (16) comprises separate strips, an additional cover layer at the bottom of the laminated magnetic conductor (10) helps to secure the entire assembly together and also helps provide a moisture barrier to protect the high permeability. The rate layer is not oxidized.

The thermally conductive portion (22) generally includes a layer of thermally conductive material (16). As shown in the second figure, the thermally conductive layer (16) is placed in close proximity to the insulating layer (14d) in the depicted embodiment. The heat conducting layer (16) can be a thin layer of highly thermally conductive metal or other material having sufficient thermal conductivity. In the particular embodiment depicted, the thermally conductive material has a thermal conductivity in the range of 200 to 500 W/(M*K), but can be substantially the surrounding material of its associated environment (eg, as in many typical Any material that has a higher thermal conductivity in the environment for air. For example, in some applications, the thermally conductive material can be a thermally conductive polymer. The amount of heat conductivity desired can vary depending on various factors, such as the heat generated by the environment and the laminated magnetic flux guide (10). For example, when less heat is generated, the environment can quickly absorb heat from the heat conducting layer and/or heat sink, and/or the electronic device mounting the laminated magnetic flux guide (10) can withstand relatively high heat, less heat conduction may be required. rate. On the other hand, when the magnetic flux guide generates more heat, the environment does not rapidly absorb heat from the heat conducting layer and/or the associated electronic device can withstand relatively low heat, greater thermal conductivity may be required. In the particular embodiment depicted, the thermally conductive layer is a thin layer of aluminum having a thickness of from about 0.01 to 0.25 angstroms. This range of values is merely exemplary, and in some applications the thickness of the thermally conductive layer can be thicker or thinner. To facilitate the fabrication of the magnetic permeability (10) using the above method, the aluminum layer can be thin enough to allow it to be provided in a roll form, but this is not strictly necessary. Aluminum is well suited for this particular application because of its high thermal conductivity, good mechanical strength, flexibility and light weight, and an effective moisture barrier. While aluminum can provide the best combination of properties for many typical applications, the high thermal conductivity layer can be formed from other materials such as other metals or other materials with high thermal conductivity.

In the depicted embodiment, the thermally conductive layer (16) is also electrically conductive. This allows the heat conducting layer (16) to function as a mask, providing further control of the magnetic flux. For example, if conductive, a magnetic field can induce eddy currents in the thermally conductive layer. This can be substantially reduced or eliminated Except for the magnetic field passing through the heat conducting layer, the objects in the environment shielding the opposite side of the heat conducting layer are not affected by the magnetic field. For example, the sixth graph shows a representative comparison map, a magnetic field M (left image) and a laminated magnetic flux guide (10) (right image) in a laminated magnetic flux guide (200) of the prior art without a heat conductive layer. The latter includes a conductive heat conducting layer (16). In this representative example, the laminated magnetic flux guides (200) and (10) are placed in close proximity to an inductive transfer coil (C) that generates a magnetic field (M). It can be seen that with the prior art laminated magnetic flux guide (200), the magnetic field (M) extends below the bottom edge of the magnetic flux guide (200). However, the laminated magnetic flux guide (10) and the heat conducting layer (16) function as the same mask to prevent the magnetic field (M) from extending beyond the heat conducting layer (16). The improved magnetic behavior of laminated magnetic flux guidance is attributed to the diamagnetic effect of the thermally conductive and electrically conductive material (16), such as, for example, aluminum or iron. This illustration shows that the laminated magnetic flux guide (10) can be configured to shield objects placed under the laminated magnetic flux guide (10), including metal (like steel), from the magnetic field (M). It can be seen that the laminated magnetic flux guide (10) can be incorporated into a remote device that receives inductive power from a wireless power supply. In such an application, the laminated magnetic flux guide can be placed in close proximity to the receiving coil on the opposite side of the transfer coil. More specifically, the laminated magnetic flux guide (10) can be placed with the cover layer (15) in close proximity to the receiver coil and the thermally conductive layer (16) on the opposite side. In such an application, the heat conducting layer (16) can function as a mask to assist in including the magnetic field transmitted by the transmitter coil. While the thermally conductive layer (16) of the particular embodiment has been shown to have good electrical conductivity, the thermally conductive layer (16) can be made of a material having a low electrical conductivity, such as, for example, a thermally conductive polymer. This alternative can be implemented if it is desired to limit the eddy currents and associated heat losses caused by the conductive material.

Where the heat conducting layer (16) is electrically conductive but is intended to limit the heat generated by the eddy current, the heat conducting layer (16) can be cut or divided into electrically isolated strips to reduce the amount of continuous material, which reduces vortices. The current is minimized and the heat loss in the heat conducting layer is minimized. As above regarding high permeability In the discussion of the rate layer (12a-d), the number and width of the strips in the heat conducting layer (16) may vary depending on various factors depending on various factors, but the comparison will be selected to be sufficiently narrow to avoid lamination. The magnetic flux guide (10) generates excessive eddy currents (and excessive heat) when subjected to the expected magnetic field.

The laminated magnetic flux guide (10) of the present invention can be coupled to other thermal management components to remove heat from the system. For example, in the specific embodiment of the fourth figure, the laminated magnetic flux guide (10) is coupled to a heat sink (30), and in the fifth figure, the laminated magnetic flux guide (10) is coupled to a The heat pipe (32) is then recoupled to a heat sink (30). The heat sink (30) and heat pipe (32) can be substantially any heat sink or heat pipe, including any conventional heat sink or heat pipe capable of providing the desired heat dissipation under the packaging constraints of this application. The heat conducting layer (16) can be bonded directly to the heat sink (30) or heat pipe (32), or a layer of electrical barrier material (not shown) can be placed therebetween. If directly coupled to the heat sink (30) or the heat pipe (32), the heat conducting layer (16) can be bonded to the heat sink (30) or the heat pipe (32) by a thermally conductive adhesive, such as, for example, a thermally conductive poly Oxygen adhesive, epoxy adhesive or transfer tape. In a particular embodiment comprising an intermediate electrically isolating layer, the insulating material can be any of the insulating materials discussed above with respect to layering (14a-d).

In another aspect, the present invention provides a method for fabricating a laminated magnetic flux guide (10). A specific embodiment of the method is described with respect to the third figure, which is based on a representative schematic of a specific embodiment of a manufacturing method for manufacturing a laminated magnetic flux guide (10). The method generally includes the steps of: providing a plurality of rolls of high permeability material; providing a roll of thermally conductive material to provide a roll of final insulation material; applying an adhesive material between adjacent layers of high permeability material, The adhesive material can function as a heat insulating material; the high magnetic permeability material and the applied adhesive are fed into a set of press rolls to combine different layers under pressure to form a pre-pressed layer; the heat transfer layer, The pre-compression layer and the final insulation material are fed into a set of pressure rollers to combine them into one under pressure. The final laminate is cut and the final laminate is cut into the desired shape. In the particular embodiment depicted, the high magnetic permeability material is a soft magnetic material comprising an amorphous and nanocrystalline alloy commercially available from Vacuumschmelze GmbH & Co. KG under the trade name VITROPERM, such as, for example, VITROPERM. 800. However, the high permeability layer can be other high permeability materials that can be supplied in rolls. In the particular embodiment depicted, the thermally conductive material is a thin layer of aluminum, but other materials discussed above may also be used.

Referring now to the third figure, the fabrication system (100) includes a high permeability material of a plurality of rolls (102a-d) that supplies a high permeability material for layering (12a-d). During manufacture, four thin (104a-d) high magnetic permeability materials are extracted from four rolls (102a-d) of high magnetic permeability material to form a four layer high permeability layer (12a-d).

In this embodiment, the insulating layer (14b-e) is formed of an insulating material that adheres and electrically isolates the high magnetic permeability layers (12a-d). To this end, the manufacturing system (100) of the present embodiment includes an in-line applicator (108) disposed downstream of the reels (102a-d). The applicator (108) is configured to apply an insulating/adhesive material to the appropriate surface of the thin webs (104a-d). More specifically, in this embodiment, the applicator (108) applies a layer of insulation when each of the webs is passed from the reels (102a-d) to the press rolls (106a-b) (discussed below). Adhesive material to the underside of the webs (104a-d). The insulating/adhesive material may be applied alternately to the top surface of the equal widths (104b-d) or simultaneously to the bottom surface of the webs (104a-d) and the top surface of the thin webs (104b-d). The applicator (108) can include a sprayer, a roller, or other mechanism capable of applying insulating material (104a-d) to the equal widths (104a-d). In this embodiment, the insulating material can be a pressure sensitive adhesive, a heat activated adhesive, or a polymer that can insulate and bond adjacent webs (104a-d). In some applications, it may be desirable to apply an insulating material to the bottom surface of the web (104d) after the press rolls (106a-b). This insulating material can be used to shape An insulating material (14d) that combines and electrically isolates the heat conducting layer (16) from the high magnetic permeability layer (12d). The insulating material used for this layer may be the same as or different from the material used to form the insulating material (14a-c).

In this particular embodiment, the high permeability thin sheets (104a-d) having the applied insulating material are then bonded together to form a pre-compression laminate (110). The thin webs (104a-d) and the insulating material can be bonded together by pressure and heat. As shown in the third figure, the coated webs (104a-d) are fed into a set of press rolls (106a-b). The pressure rolls (106a-b) are configured to apply the correct amount of pressure (and possibly heat) to cause the insulation/adhesive material to bond the thin webs (104a-d) into a pre-compression laminate (110). In applications where heating is applied, one or both of the press rolls (106a-b) may be heated, or a separate heat source may be incorporated into the system. For example, a heat or radiant heater can be placed before the pressure rollers (106a-b) to apply the correct amount of heat to activate or otherwise assist the insulating material to adhesively bond adjacent layers and form an insulating layer (14a- d). In some applications, it may be desirable to provide a non-stick coating of the lower press roll (106b) to prevent accumulation of insulating material over the lower press roll (106b).

In the depicted embodiment, the pre-laminate (110) is divided into narrow strips including a plurality of longitudinal elongate spacers to create electrical isolation between adjacent strips. In this particular embodiment, the pre-laminates (110) are cut into lengths and the strips are separated at an in-line cutting station (112) located downstream of the press rolls (106a-b). However, the high permeability material layer and possibly the insulating layer can be divided into strips at other times. For example, the reel of high permeability material may be pre-segmented or may be slit at a processing line before the web (104a-b) is fed into the twisting rolls (106a-b). Prior to forming the final laminate (120), the strips are spaced apart so that the strips are electrically isolated from each other within the final laminate.

In a particular embodiment, the method includes the step of annealing the high permeability material Gather. The high permeability material can be substantially annealed at any point during its manufacture, such as, for example, before or after being rolled into a roll, and before or after being cut into narrow strips. In a specific embodiment of an adhesive/isolation material that is not damaged by the annealing process, the high permeability material can be annealed prior to formation of the pre-laminated laminate. In a specific embodiment where the coating has a coating and the thermally conductive layer is not damaged by the annealing process, the high permeability material can be annealed after the final laminate is formed. In the depicted embodiment, the high permeability material is annealed prior to being rolled into a roll (102a-d). In an application where it is desired to anneal the high permeability material later, an on-line annealing station can be incorporated into the fabrication system (100). For example, an annealing station can be placed downstream of the drum (102a-d) and upstream of the applicator (108).

The pre-laminated laminate (110) is cut into strips and separated, a cover layer (15) is applied over the pre-compression laminate (110), and a thermal conductive layer (16) is applied to the pre-compression laminate (110). ) below. In this embodiment, a cover layer (15) and a heat conductive layer (16) are simultaneously applied to the pre-compression layer (110). Referring now to the third figure, the cover layer (15) is provided in the form of a roll (114) positioned such that the cover layer (15) is to be withdrawn from the roll and secured to the second set of press rolls (116a-b) to The pre-compacted laminate (110). For example, the cover layer (15) of the particular embodiment depicted may be a roll of PET. In this embodiment, the cover layer (15) is previously provided with an adhesive layer for bonding the cover layer (15) to the top surface of the pre-compression laminate. For example, a pressure sensitive adhesive or a heat activated adhesive can be applied to the PET cover prior to being rolled into a roll. The adhesive may additionally be applied to the cover layer (15) after the material has been drawn from the roll (114). For example, an adhesive applicator (not shown) can be placed between the roll (114) and the second press roll (116a-b). Similarly, the heat conducting layer (16) is provided in a roll (118). The roll (118) can be configured to feed the thermally conductive material to the bottom surface of the pre-compression laminate (110) prior to the second press roll (116a-b). An insulating layer (14d) can be used to secure the thermally conductive layer (16) to the pre-pressed layer (110). For example It is said that the pressure or heat required to activate the adhesive in the insulating layer (14d) can be applied by the second pressure roller (11ba-b). Although the cover layer (15) and the heat transfer layer (16) are applied using a second set of pressure rollers (106a-b) in this embodiment, one or both can alternatively be applied using the first pressure roller (106a-b). . For example, in an alternative embodiment, the high permeability layer (12a-d) can be divided into long strips, and the cover layer (15) and the heat conductive layer (16) can be on the first press roll (106a-b) ) was previously sent to the thin component. In this alternative embodiment, a single set of press rolls can simultaneously join all of the layers to form a continuous web of a final laminate (120).

After the different layers have been joined by the second pressure roller (116a-b), the web (104a-b), the insulating layer (14a-d), the cover layer (15) and the heat conducting layer (16) together form a final laminate ( 120) continuous footage. The continuous web of this final laminate (120) can then be cut to form the final laminated magnetic flux guide (10). In this particular embodiment, the continuous web of the final laminate (120) is cut into laminated magnetic flux guides (10) at the cutting station (122). The cutting station (122) cuts the web laterally to divide the continuous web into intermittent sections depending on the size of the desired laminated magnetic flux guide (10). If the continuous web is larger than the desired size of the laminated magnetic flux guide, the cutting station (122) can also be configured to perform a longitudinal cut. For example, the continuous web of the final laminate (120) can be configured to double the desired width of the laminated magnetic flux guide (10). In this application example, in addition to the lateral cutting, the cutting station can perform longitudinal cutting to divide the longitudinal direction into two halves. The cutting station (122) can include substantially any device capable of cutting the final laminate (120) web into individual laminated magnetic flux guides (10). For example, the cutting station (122) can include a conventional die cutter. Alternatively, the cutting step can be performed by adding a cutter to the second set of pressure rollers (116a-b).

In some applications, it may be desirable to divide the thermally conductive layer (16) into separate strips. Although not shown, this can be achieved by introducing the heat conducting layer (16) prior to the first set of press rolls (106a-b). Create a program. In such an application, the thermally conductive layer (16) will be included in the pre-compression laminate (110) and the in-line cutting station (112) will cut the thermally conductive layer (16) and along with the remainder of the pre-compression laminate (110). separate.

In some applications, it may be desirable to add a bottom cover layer (not shown) over the outer surface of the heat conductive layer (16). This is particularly advantageous if the heat conducting layer (16) has been divided into separate strips. In such an application, the bottom cover layer can cooperate with the top cover layer (15) to secure the laminated magnetic flux guides (10) together. A bottom cover layer (not shown) may be attached to the final laminate (120) by introducing the bottom cover layer prior to the second set of pressure rolls (116a-b), for example, a roll (not shown) of the bottom cover layer. The material can be placed to allow the bottom cover material to be pulled to a position along the outer surface of the thermally conductive layer (16) prior to entering the second set of pressure rolls (116a-b). This will allow the bottom cover to be bonded to the final laminate (120) by a second set of press rolls (116a-b). If desired, the top cover layer (16) and the bottom cover layer (not shown) may be sized to extend beyond the intermediate level such that the top cover layer (16) and the bottom cover layer are at least partially bonded along their edges. together. In applications where it is desirable to combine all of the edges of the bottom cover and the top cover, the top cover and the bottom cover may be applied after the final laminate (120) has been cut at the cutting station (118).

The above is a description of specific embodiments of the invention. There may be many variations and modifications without departing from the spirit of the invention as defined by the appended claims, and the broader scope of the invention. The description is presented for the purpose of illustration and description, and is not intended to For example, without limitation, any (singular or plural) individual elements of the invention may be substituted by alternative elements, provided that they provide substantially similar functionality or otherwise provide suitable operation. By way of example, this includes alternative components that are currently known, such as those currently known to those skilled in the art, and alternative components that may be developed in the future, such as, for example, once developed, familiarize themselves with those skilled in the art. It can be recognized as an alternative component. Further, the disclosed embodiments include the plurality of features described together and together provide a benefit. The invention is not limited to the specific embodiments, including all such features, or to the specific embodiments, including all of the claimed advantages, unless otherwise indicated. Any element of the patentable scope referred to in the singular, for example, "a", "the", "said" or "said" shall not be construed as limiting the element to the singular.

10‧‧‧ laminated magnetic flux guidance

12a-d‧‧‧High magnetic permeability material

14a-d‧‧‧Electrical insulation materials

15‧‧‧ Coverage

16‧‧‧heat conduction layer

Claims (24)

A laminated magnetic flux guide comprising: a plurality of layers of high magnetic permeability material; a plurality of layers of electrically insulating material, the layers of the high magnetic permeability material and the layers of the insulating materials are arranged in an overlapping manner; and a heat conducting layer is in close proximity These intersections are placed in a stack. The magnetic flux guide of claim 1, wherein the plurality of layers of high permeability material comprise a plurality of electrically isolated strips. The magnetic flux guide of claim 2, wherein the heat conducting layer is a layer of metal. The magnetic flux guide of claim 2, wherein the heat conducting layer is a layer of aluminum. The magnetic flux guide of claim 4, further comprising a cover layer adjacent to the overlap stack, wherein the cover layer and the heat transfer layer are disposed on opposite sides of the overlap layer, the cover layer providing a wet Gas barrier. The magnetic flux guide of claim 5, wherein each of the plurality of layers of insulating material is an adhesive. The magnetic flux guiding of claim 6 further includes a layer of electrically insulating material disposed between the overlapping layers and the thermally conductive layer. An assembly comprising: an inductive coil configured to generate or receive a magnetic field; and a laminated magnetic flux guide disposed proximate the inductive coil, the laminated magnetic flux guide having: a magnetically conductive portion, including an overlap a layer of high magnetic permeability material and a layer of electrically insulating material; and a thermally conductive layer disposed immediately adjacent to the other side of the inductive coil. The assembly of claim 8 wherein the heat conducting layer is a layer of metal. The assembly of claim 8 wherein the heat conducting layer is a layer of aluminum. The assembly of claim 9, further comprising a cover layer adjacent to the magnetically permeable portion, wherein the cover layer and the heat conductive layer are disposed on opposite sides of the magnetically permeable portion. An assembly according to claim 11 wherein each of said layers of electrically insulating material is an adhesive bonded to an adjacent pair of said layers of high magnetic permeability material. The assembly of claim 12, further comprising a layer of electrically insulating material disposed between the magnetic flux portion and the thermally conductive layer. The assembly of claim 8 wherein the plurality of layers of high permeability material comprise a plurality of electrically isolated strips. The assembly of claim 14, wherein the heat conducting layer comprises a plurality of electrically isolated strips. A method for making a laminated magnetic flux guide comprising the steps of: providing a plurality of high permeability materials, each roll comprising a continuous web of the high permeability material; providing an electrically isolating layer in the continuous web Between the thin web and the release layer are fed into a press roll to form a pre-compressed layer; a roll of continuous conductive material is provided; a roll of continuous cover material is provided; and the conductive material, the pre-pressed layer, and the The cover material is fed into a press roll to form a final laminate. The method of claim 16, further comprising the step of dividing the pre-laminated sheet into electrically isolated strips. The method of claim 17, wherein the dividing step comprises the step of cutting the pre-laminated sheet into a plurality of strips and separating the strips by a sufficient distance to provide electrical isolation of adjacent strips. The method of claim 18, wherein the heat conducting layer is a metal. The method of claim 18, wherein the heat conducting layer is aluminum. The method of claim 16 wherein the adjacent pair of continuous webs have a pair of joining surfaces; and wherein the step of providing an insulating layer between the continuous webs comprises performing an electrically insulating adhesive to each pair of joining surfaces At least one side. The method of claim 16, wherein the step of providing an insulating layer between the continuous webs comprises the steps of: providing a plurality of rolls of insulating material, each roll of insulating material comprising a continuous web of electrically insulating material; Prior to feeding the thin web and insulating layer into the press roll to form a pre-compacted laminate, an insulating material layer is placed between each pair of adjacent high permeability material sheets. The method of claim 22, wherein each pair of adjacent high magnetic permeability continuous webs and a continuous layer of insulating layer have a pair of bonding surfaces; and wherein the step of providing an insulating layer comprises performing an electrically insulating adhesive to each At least one of the sides of the joint surface. The method of claim 16, further comprising the step of cutting the final laminate into a laminated magnetic flux guide.