WO2019227645A1 - 一种无线充电模组用屏蔽片及其制备方法 - Google Patents

一种无线充电模组用屏蔽片及其制备方法 Download PDF

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Publication number
WO2019227645A1
WO2019227645A1 PCT/CN2018/097364 CN2018097364W WO2019227645A1 WO 2019227645 A1 WO2019227645 A1 WO 2019227645A1 CN 2018097364 W CN2018097364 W CN 2018097364W WO 2019227645 A1 WO2019227645 A1 WO 2019227645A1
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Prior art keywords
magnetic sheet
sheet
nanocrystalline
wireless charging
charging module
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PCT/CN2018/097364
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English (en)
French (fr)
Inventor
庞治华
王磊
李家洪
康来利
王帅
刘开煌
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信维通信（江苏）有限公司
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Publication of WO2019227645A1 publication Critical patent/WO2019227645A1/zh

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Classifications

    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F38/00—Adaptations of transformers or inductances for specific applications or functions
    • H01F38/14—Inductive couplings
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F27/00—Details of transformers or inductances, in general
    • H01F27/34—Special means for preventing or reducing unwanted electric or magnetic effects, e.g. no-load losses, reactive currents, harmonics, oscillations, leakage fields
    • H01F27/36—Electric or magnetic shields or screens
    • H01F27/361—Electric or magnetic shields or screens made of combinations of electrically conductive material and ferromagnetic material
    • H02J7/025—
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B3/00—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form
    • B32B3/10—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by a discontinuous layer, i.e. formed of separate pieces of material
    • B32B3/14—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by a discontinuous layer, i.e. formed of separate pieces of material characterised by a face layer formed of separate pieces of material which are juxtaposed side-by-side
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B3/00—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form
    • B32B3/26—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by a particular shape of the outline of the cross-section of a continuous layer; characterised by a layer with cavities or internal voids ; characterised by an apertured layer
    • B32B3/266—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by a particular shape of the outline of the cross-section of a continuous layer; characterised by a layer with cavities or internal voids ; characterised by an apertured layer characterised by an apertured layer, the apertures going through the whole thickness of the layer, e.g. expanded metal, perforated layer, slit layer regular cells B32B3/12
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B7/00—Layered products characterised by the relation between layers; Layered products characterised by the relative orientation of features between layers, or by the relative values of a measurable parameter between layers, i.e. products comprising layers having different physical, chemical or physicochemical properties; Layered products characterised by the interconnection of layers
    • B32B7/04—Interconnection of layers
    • B32B7/12—Interconnection of layers using interposed adhesives or interposed materials with bonding properties
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F27/00—Details of transformers or inductances, in general
    • H01F27/24—Magnetic cores
    • H01F27/245—Magnetic cores made from sheets, e.g. grain-oriented
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F27/00—Details of transformers or inductances, in general
    • H01F27/34—Special means for preventing or reducing unwanted electric or magnetic effects, e.g. no-load losses, reactive currents, harmonics, oscillations, leakage fields
    • H01F27/36—Electric or magnetic shields or screens
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F27/00—Details of transformers or inductances, in general
    • H01F27/34—Special means for preventing or reducing unwanted electric or magnetic effects, e.g. no-load losses, reactive currents, harmonics, oscillations, leakage fields
    • H01F27/36—Electric or magnetic shields or screens
    • H01F27/366—Electric or magnetic shields or screens made of ferromagnetic material
    • H02J5/005—
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02J—CIRCUIT ARRANGEMENTS OR SYSTEMS FOR SUPPLYING OR DISTRIBUTING ELECTRIC POWER; SYSTEMS FOR STORING ELECTRIC ENERGY
    • H02J50/00—Circuit arrangements or systems for wireless supply or distribution of electric power
    • H02J50/10—Circuit arrangements or systems for wireless supply or distribution of electric power using inductive coupling
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02J—CIRCUIT ARRANGEMENTS OR SYSTEMS FOR SUPPLYING OR DISTRIBUTING ELECTRIC POWER; SYSTEMS FOR STORING ELECTRIC ENERGY
    • H02J50/00—Circuit arrangements or systems for wireless supply or distribution of electric power
    • H02J50/10—Circuit arrangements or systems for wireless supply or distribution of electric power using inductive coupling
    • H02J50/12—Circuit arrangements or systems for wireless supply or distribution of electric power using inductive coupling of the resonant type
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02J—CIRCUIT ARRANGEMENTS OR SYSTEMS FOR SUPPLYING OR DISTRIBUTING ELECTRIC POWER; SYSTEMS FOR STORING ELECTRIC ENERGY
    • H02J50/00—Circuit arrangements or systems for wireless supply or distribution of electric power
    • H02J50/70—Circuit arrangements or systems for wireless supply or distribution of electric power involving the reduction of electric, magnetic or electromagnetic leakage fields
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/20—Properties of the layers or laminate having particular electrical or magnetic properties, e.g. piezoelectric
    • B32B2307/208—Magnetic, paramagnetic
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/20—Properties of the layers or laminate having particular electrical or magnetic properties, e.g. piezoelectric
    • B32B2307/212—Electromagnetic interference shielding
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F27/00—Details of transformers or inductances, in general
    • H01F27/34—Special means for preventing or reducing unwanted electric or magnetic effects, e.g. no-load losses, reactive currents, harmonics, oscillations, leakage fields
    • H01F2027/348—Preventing eddy currents

Definitions

  • the invention relates to the technical field of wireless charging, in particular to a shielding sheet for a wireless charging module and a preparation method thereof.
  • Wireless charging technology is a method that uses near-field electromagnetic induction to transmit energy from the transmitting end to the wireless charging receiving coil through a magnetic field. Compared with electric field coupling, the wireless charging technology based on the magnetic field coupling principle is closer to the conventional resonant switching power supply.
  • magnetic materials need to be used.
  • the role of magnetic materials is to distribute the magnetic field in high-permeability magnetic materials, prevent the magnetic field from passing through the magnetic materials and reach the interior of the electronic equipment, and cause the metal (battery) and other components inside the electronic equipment to absorb the magnetic field, resulting in energy loss and electromagnetic interference.
  • the location next to the wireless charging coil is generally the battery.
  • the alternating magnetic field generated by the transmitting coil passes through the charging module and reaches the metal layer on the surface of the battery, an induced current will be generated. This is the so-called "eddy current”.
  • This eddy current will generate a magnetic field that cancels out the change of the magnetic field at the transmitting end, which will cause the voltage induced in the receiving coil to drop; and the eddy current will convert the energy of the magnetic field into heat, making the mobile phone battery very hot. Therefore, in order to achieve wireless charging of the mobile phone, it is necessary to place a "isolating magnetic field" device between the receiving coil and the mobile phone battery to avoid the magnetic field from affecting the battery.
  • the receiver of Samsung mobile phone wireless charging adopts the amorphous electromagnetic shielding sheet technology provided by Amotech, and the charging efficiency reaches more than 70%.
  • the technical problem to be solved by the present invention is to provide a shielding sheet for a wireless charging module which is small in size and capable of improving charging efficiency, and a method for preparing the shielding sheet for a wireless charging module.
  • a shielding sheet for a wireless charging module which is composed of an outer ring magnetic sheet and a center magnetic sheet.
  • the outer ring magnetic sheet is provided with a through hole, and the center magnetic sheet and the The through hole is adapted, one end of the center magnetic sheet is located in the through hole, and the top surface of the outer ring magnetic sheet is coplanar with the top surface of the center magnetic sheet;
  • the nanocrystalline strips are laminated and two adjacent nanocrystalline strips are bonded by an insulating glue.
  • the magnetic permeability of the central magnetic sheet is smaller than the magnetic permeability of the outer magnetic sheet. There is an air gap.
  • the present invention also adopts the following technical solutions: a method for preparing a shielding sheet for a wireless charging module,
  • Step 1 Provide nano-crystalline strip and heat-treat the nano-crystalline strip
  • Step 2 Glue the nanocrystalline strip after Step 1;
  • Step 3 Laminate N nanocrystalline strips and bond two adjacent nanocrystalline strips to obtain a first nanocrystalline magnetic sheet, where N is an integer greater than 2; stack M nanocrystalline strips And bonding two adjacent nanocrystalline strips to obtain a second nanocrystalline magnetic sheet, where M is an integer greater than 3 and the value of M is greater than N;
  • Step 4 Perform die-cutting contour and through-hole processing on the first nanocrystalline magnetic sheet to obtain an outer ring magnetic sheet;
  • Step 5 Insert one end of the central magnetic sheet into the through hole, and make the top surface of the central magnetic sheet and the top surface of the outer ring magnetic sheet coplanar.
  • the beneficial effect of the present invention is that, because the direction of the outer ring magnetic sheet is perpendicular to the direction of the induced eddy current, and there is an insulating glue between the laminated nanocrystalline strips, no matter how high the magnetic loss ⁇ ”of the outer ring magnetic sheet is, it will not Generates a long free path eddy current, so the outer ring magnetic sheet not only maintains high magnetic permeability but also has low eddy loss.
  • the magnetic field generates eddy current in the center magnetic sheet within the magnetic sheet surface
  • the central magnetic sheet is provided with a grid-shaped air gap, which can suppress the generation of long free path eddy currents, thereby reducing eddy loss.
  • the shielding sheet of the present invention has the same shielding performance as the conventional magnetic shielding sheet, and has a The number of laminated magnetic sheets is smaller, and the center magnetic sheet is just embedded in the center of the coil, which does not affect the thickness of the module, so it is conducive to the miniaturization of the shielding sheet; meanwhile, the charging efficiency is also improved; in addition, during the production process of the shielding sheet There is no need to use the traditional "crushing magnetic" process, which is beneficial to reducing the manufacturing process of the shielding sheet and reducing the manufacturing cost of the shielding sheet.
  • FIG. 1 is a cross-sectional (schematic) view of a shielding sheet for a wireless charging module according to a first embodiment of the present invention
  • FIG. 2 is a working principle (schematic) diagram of a shielding sheet for a wireless charging module according to the first embodiment of the present invention.
  • the shielding sheet includes an outer ring magnetic sheet with high magnetic permeability and a central magnetic sheet with low magnetic permeability; the outer magnetic sheet is provided with a through hole, and one end of the central magnetic sheet is located in the through hole.
  • a shielding sheet for a wireless charging module is composed of an outer ring magnetic sheet 1 and a center magnetic sheet 2.
  • the outer ring magnetic sheet 1 is provided with a through hole 3.
  • the through hole 3 is adapted, one end of the center magnetic sheet 2 is located in the through hole 3, and the top surface of the outer ring magnetic sheet 1 and the top surface of the center magnetic sheet 2 are coplanar; the outer ring magnetic sheet 1 and
  • the central magnetic sheet 2 is formed by stacking a plurality of nanocrystalline strips and two adjacent nanocrystalline strips are bonded by an insulating glue.
  • the magnetic permeability of the central magnetic sheet 2 is smaller than that of the outer magnetic sheet 1.
  • An air gap is provided on the nanocrystalline strip of the central magnetic sheet 2.
  • the structure / working principle of the present invention is briefly described as follows: magnetic lines of force perpendicular to the outer magnetic disk 1 will induce the central magnetic disk 2 to generate eddy currents parallel to the outer magnetic disk 1, and the presence of an air gap in the central magnetic disk 2 will suppress eddy currents.
  • the magnetic field lines parallel to the outer magnetic disk 1 will induce the outer magnetic disk 1 to generate eddy currents perpendicular to the outer magnetic disk 1. Because the nanocrystalline layer itself in the outer magnetic disk 1 is very thin ( (Only 10-20 ⁇ m), and there is an insulating polymer glue between the layers, it is difficult for the outer ring magnetic sheet 1 to generate a large eddy current.
  • the beneficial effect of the present invention is that the magnetic permeability ⁇ 'of the outer magnetic sheet will be very high because the outer magnetic sheet is perpendicular to the direction of the induced eddy current and there is an insulating glue between the laminated nanocrystalline strips. It does not generate long free path eddy current itself, so that the shielding sheet has ultra-high magnetic permeability and low loss.
  • the invention Air gaps can inhibit the generation of long free path vortices.
  • the new structure shielding sheet has fewer nanocrystalline strips laminated on the outer ring magnetic sheet in the same shielding performance under the same shielding performance, and the center magnetic sheet is just embedded in the coil.
  • the center does not affect the thickness of the module, so it is conducive to the miniaturization of the shielding sheet; at the same time, the charging efficiency is also improved; in addition, the traditional "magnetic crushing" process is not required in the production process of the shielding sheet, which is beneficial to reducing the shielding sheet.
  • the manufacturing process reduces the manufacturing cost of the shielding sheet.
  • an adhesive layer 5 is provided on the top surface of the outer ring magnetic sheet 1, and the top surface of the central magnetic sheet 2 is connected to the adhesive layer 5.
  • outer ring magnetic sheet 1 is formed by stacking 2 or 3 nanocrystalline strips; the central magnetic sheet 2 is formed by stacking 3-12 nanocrystalline strips.
  • the number of layers of the nanocrystalline strip in the outer magnetic sheet is much less than the number of layers of the conventional nanocrystalline shielding sheet, which is beneficial to the miniaturization of the shielding sheet.
  • the air gap is in a grid shape.
  • the magnetic permeability of the outer magnetic sheet 1 is greater than or equal to 10,000, and the magnetic permeability of the central magnetic sheet 2 is 200-6000.
  • Step 1 Provide nano-crystalline strip and heat-treat the nano-crystalline strip
  • Step 2 Glue the nanocrystalline strip after Step 1;
  • Step 3 Laminate N nanocrystalline strips and bond two adjacent nanocrystalline strips to obtain a first nanocrystalline magnetic sheet, where N is an integer greater than 2; stack M nanocrystalline strips And bonding two adjacent nanocrystalline strips to obtain a second nanocrystalline magnetic sheet, where M is an integer greater than 3 and the value of M is greater than N;
  • Step 4 Perform die-cutting contour and through-hole processing on the first nanocrystalline magnetic sheet to obtain an outer ring magnetic sheet;
  • Step 5 Insert one end of the central magnetic sheet into the through hole, and make the top surface of the central magnetic sheet and the top surface of the outer ring magnetic sheet coplanar.
  • step 5 the step of attaching the top surface of the central magnetic sheet and the top surface of the outer magnetic sheet to the same adhesive layer is further included.
  • the N is 2 or 3
  • the M is any value from 3-12.
  • the M is any value from 3-12.
  • step 1 the nanocrystalline strip is heat-treated by using a heat treatment furnace; and before the nanocrystal strip is put into the heat treatment furnace, a step of rolling the nanocrystal strip is also provided.
  • step 2 a roll-to-roll coating process is used to cover the nanocrystalline strip.
  • a first embodiment of the present invention is: a shielding sheet for a wireless charging module, which is composed of an outer ring magnetic sheet 1 and a center magnetic sheet 2, and an outer ring magnetic sheet 1 is provided with a through hole 3
  • the central magnetic sheet 2 is adapted to the through-hole 3, one end of the central magnetic sheet 2 is located in the through-hole 3, and the top surface of the outer magnetic sheet 1 and the top surface of the central magnetic sheet 2 are coplanar;
  • the outer ring magnetic sheet 1 and the central magnetic sheet 2 are each formed by stacking a plurality of nanocrystalline strips and two adjacent nanocrystalline strips are bonded by an insulating glue.
  • the magnetic permeability of the central magnetic sheet 2 is smaller than that of the outer
  • the magnetic permeability of the ring magnetic sheet 1 is provided with an air gap on the nanocrystalline strip of the central magnetic sheet 2.
  • FIG. 2 is a working principle diagram of the shielding sheet of this embodiment. As can be seen from the figure, the magnetic lines of force have been deflected by the shielding sheet.
  • Adjacent two nanocrystalline strips in the outer magnetic sheet 1 are bonded with an insulating polymer glue, and two adjacent nanocrystalline strips in the central magnetic sheet 2 are bonded with an insulating polymer glue.
  • the thickness of the nanocrystalline strip is 10 ⁇ 25 ⁇ m.
  • an adhesive layer 5 is provided on the top surface of the outer ring magnetic sheet 1, and the top surface of the central magnetic sheet 2 is connected to the adhesive layer 5.
  • the outer ring magnetic sheet 1 is formed by stacking two or three nanocrystalline strips; the central magnetic sheet 2 is formed by stacking 3-12 nanocrystalline strips.
  • the central magnetic sheet 2 is formed by laminating 6-12 nanocrystalline ribbons.
  • the air gap is in a grid shape.
  • the air gap may have other shapes, such as a triangular frame shape.
  • the magnetic permeability of the outer magnetic sheet 1 is greater than or equal to 10,000, and the magnetic permeability of the central magnetic sheet 2 is 200-6000.
  • the central magnetic sheet 2 of the shielding sheet is located in a hollow area of the charging coil 4, and the charging coil 4 is bonded to the outer magnetic sheet 1 of the shielding sheet through a pressure-sensitive adhesive.
  • the inner edge of the charging coil 4 is in contact with the outer edge of the central magnetic sheet 2.
  • the second embodiment of the present invention is: a method for preparing a shielding sheet for a wireless charging module
  • Step 1 Provide nano-crystalline strip and heat-treat the nano-crystalline strip
  • Step 2 Glue the nanocrystalline strip after Step 1;
  • Step 3 Laminate N nanocrystalline strips and bond two adjacent nanocrystalline strips to obtain a first nanocrystalline magnetic sheet, where N is an integer greater than 2; stack M nanocrystalline strips And bonding two adjacent nanocrystalline strips to obtain a second nanocrystalline magnetic sheet, where M is an integer greater than 3 and the value of M is greater than N;
  • Step 4 Perform die-cutting contour and through-hole processing on the first nanocrystalline magnetic sheet to obtain an outer ring magnetic sheet;
  • the performance requirements of the central magnetic sheet are as follows: permeability ⁇ 'Is 200 ⁇ 2000, magnetic loss ⁇ " ⁇ 200;
  • Step 5 Insert one end of the central magnetic sheet into the through hole, and make the top surface of the central magnetic sheet and the top surface of the outer ring magnetic sheet coplanar.
  • step 5 the step of attaching the top surface of the central magnetic sheet and the top surface of the outer magnetic sheet to the same adhesive layer is further included.
  • the N is 2 or 3, and the M is any value from 3-12.
  • the inventor made a batch of samples and tested them.
  • Nanocrystalline alloy strip grade 1K107b, thickness is 20 ⁇ m.
  • the nanocrystalline ribbon was heat-treated using a nitrogen furnace.
  • the specific process of heat treatment is as follows: first, the nanocrystalline strip is heated to 450 to 600 ° C with the furnace, and then maintained for 2 hours, and then cooled to 250 ° C at a rate of 500 ° C / h and released.
  • the other part of the single-sided coated tape was bonded to obtain 6 layers, 9 layers, and 12 layers of the second nanocrystalline magnetic sheet; and the die cutting machine was used for contour die cutting and air gap die cutting to make the second nanocrystalline magnetic sheet.
  • a grid-shaped air gap of 0.01 to 0.2 mm is formed, and the magnetic parameters of the second nanocrystalline magnetic sheet after die cutting are shown in Table 2.
  • One end of the second nanocrystalline magnetic sheet is inserted into the through hole of the first nanocrystalline magnetic sheet, so that the top surfaces of the first and second nanocrystalline magnetic sheets are coplanar, and the top surfaces of the two are connected by an adhesive layer.
  • the overall inductance of the wireless charging module using the shielding sheet of the present invention is higher than that of Comparative Samples 8 and 9, and the Q value also increases significantly.
  • the 5W platform was used to compare the charging efficiency of samples 1-9.
  • the test results are shown in Table 4.
  • the charging efficiency of a wireless charging module using the shielding sheet of the present invention is much higher than that of a wireless charging module using a conventional shielding sheet of the same number of layers. Compared with 5 layers of nanocrystalline magnetic materials, the charging efficiency is also improved by about 2%.
  • the shielding sheet for a wireless charging module provided by the present invention and a preparation method thereof compared with a conventional magnetic shielding sheet, under the same shielding performance conditions, the outer ring magnetic sheet of the shielding sheet of the present invention is laminated.
  • the number of nanocrystalline strips is smaller, and the center magnetic sheet is just embedded in the center of the coil, which does not affect the thickness of the module, so it is conducive to the miniaturization of the shielding sheet; meanwhile, the charging efficiency is also improved; in addition, during the production process of the shielding sheet There is no need to use the traditional "crushing magnetic" process, which is beneficial to reducing the manufacturing process of the shielding sheet and reducing the manufacturing cost of the shielding sheet.

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  • Engineering & Computer Science (AREA)
  • Power Engineering (AREA)
  • Computer Networks & Wireless Communication (AREA)
  • Physics & Mathematics (AREA)
  • Electromagnetism (AREA)
  • Shielding Devices Or Components To Electric Or Magnetic Fields (AREA)
  • Regulation Of General Use Transformers (AREA)

Abstract

一种无线充电模组用屏蔽片及其制备方法，由外圈磁片（1）和中心磁片（2）构成，外圈磁片（1）上设有贯穿孔（3），所述中心磁片（2）与所述贯穿孔（3）相适配，中心磁片（2）的一端位于所述贯穿孔（3）中，外圈磁片（1）的顶面与中心磁片（2）的顶面共面；所述外圈磁片（1）和所述中心磁片（2）分别由多个纳米晶带材层叠而成且相邻两个纳米晶带材通过绝缘胶粘接，中心磁片（2）的磁导率小于外圈磁片（1）的磁导率，所述中心磁片（2）的纳米晶带材上设有气隙。相比于与传统的纳米晶屏蔽片，该屏蔽片中外圈磁片（1）层叠的纳米晶带材数量更少，有利于屏蔽片的小型化；同时充电效率还有所提升；有利于减少屏蔽片的制程，降低屏蔽片的制造成本。

Description

一种无线充电模组用屏蔽片及其制备方法 技术领域
本发明涉及无线充电技术领域，尤其涉及一种无线充电模组用屏蔽片及其制备方法。
 背景技术
无线充电技术是利用近场电磁感应，由发射端将能量通过磁场传输至无线充电接收线圈一种方法。相对于电场耦合来讲，磁场耦合原理的无线充电技术，更接近于常规的谐振式开关电源。
为得到较高的充电效率、降低充电时电磁场对电子设备的影响，需要使用磁性材料。磁性材料的作用就是使磁场在高磁导率的磁性材料中分布，阻止磁场穿过磁性材料到达电子设备内部，造成电子设备内部金属（电池）等零部件吸收磁场从而产生能量损失及电磁干扰。以手机为例，紧挨无线充电线圈的位置一般是电池，当发射线圈产生的交变磁场穿过充电模组抵达电池表面金属层时，就会产生感应电流，这就是所谓的“涡流”，这个涡流会产生一个跟发射端磁场变化相抵消的磁场，使得接收线圈感应电压下降；并且该涡流会把磁场的能量转变成热量，使得手机电池变得非常热。因此，为了实现手机的无线充电，就必须在接收线圈和手机电池之间放置一个“隔离磁场”的装置，用来避免磁场影响电池。三星手机无线充电的接收端就采用了Amotech提供的非晶电磁屏蔽片技术，充电效率达到70%以上。Amotech技术方案中考虑到非晶磁导率和磁损耗太高，故采用了压力碎磁使非晶、纳米晶磁导率μ’降低，从而使磁损耗μ”降低到可以接受的范围（≤200），降低磁性材料本身的涡流损耗。相应的，由于μ’的降低，从而导致单层磁性材料的导磁性能下降，所以目前采用该技术方案生产的无线充电用屏蔽片需要层叠较高层数避免漏磁造成的损耗增加的问题。
 技术问题
本发明所要解决的技术问题是：提供一种体积小且能够提高充电效率的无线充电模组用屏蔽片，以及该无线充电模组用屏蔽片的制备方法。
 技术解决方案
为了解决上述技术问题，本发明采用的技术方案为：一种无线充电模组用屏蔽片，由外圈磁片和中心磁片构成，外圈磁片上设有贯穿孔，所述中心磁片与所述贯穿孔相适配，中心磁片的一端位于所述贯穿孔中，外圈磁片的顶面与中心磁片的顶面共面；所述外圈磁片和所述中心磁片分别由多个纳米晶带材层叠而成且相邻两个纳米晶带材通过绝缘胶粘接，中心磁片的磁导率小于外圈磁片的磁导率，所述中心磁片的纳米晶带材上设有气隙。
为了解决上述技术问题，本发明还采用以下技术方案：一种无线充电模组用屏蔽片的制备方法，
步骤1：提供纳米晶带材，并对纳米晶带材进行热处理；
步骤2：对经过步骤1的纳米晶带材进行覆胶；
步骤3：将N个纳米晶带材进行层叠，并使相邻两个纳米晶带材粘接，得到第一纳米晶磁片，N为大于2的整数；将M个纳米晶带材进行层叠，并使相邻两个纳米晶带材粘接，得到第二纳米晶磁片，M为大于3的整数且M的数值大于N的数值；
步骤4：对第一纳米晶磁片进行模切轮廓和贯穿孔处理，得到外圈磁片；
对第二纳米晶磁片进行模切轮廓处理以及模切气隙处理，得到中心磁片，其中，所述中心磁片与所述贯穿孔相适配；
步骤5：将中心磁片的一端插入所述贯穿孔中，并使中心磁片的顶面与所述外圈磁片的顶面共面。
 有益效果
本发明的有益效果在于：由于外圈磁片与感应涡流的方向垂直，同时层叠纳米晶带材之间存在绝缘胶，所以无论外圈磁片磁损耗μ”有多高，其本身并不会产生长自由程涡流，所以外圈磁片既保持了超高的导磁性能同时又能有较低的涡损；此外，虽然磁场在中心磁片产生涡流是在磁片面内，但本发明在中心磁片设有网格状的气隙，会抑制长自由程涡流的产生，从而降低涡损。本发明屏蔽片相比于与传统的磁性屏蔽片，在相同的屏蔽性能的条件下，外圈磁片层叠的数量更少，而中心磁片恰好镶嵌于线圈中心并不影响模组的厚度，所以有利于屏蔽片的小型化；同时充电效率还有所提升；另外，在屏蔽片生产过程中无需使用传统的“碎磁”工艺，有利于减少屏蔽片的制程，降低屏蔽片的制造成本。
 附图说明
图1为本发明实施例一的无线充电模组用屏蔽片的剖视（示意）图；
图2为本发明实施例一的无线充电模组用屏蔽片工作原理（示意）图。
标号说明：
1、外圈磁片；    2、中心磁片；    3、贯穿孔；    4、充电线圈
5、胶层。
 本发明的实施方式
为详细说明本发明的技术内容、所实现目的及效果，以下结合实施方式并配合附图予以说明。
本发明最关键的构思在于：屏蔽片包括高磁导率的外圈磁片和低磁导率的中心磁片；外圈磁片设置贯穿孔，中心磁片的一端位于贯穿孔内。
请参照图1图2，一种无线充电模组用屏蔽片，由外圈磁片1和中心磁片2构成，外圈磁片1上设有贯穿孔3，所述中心磁片2与所述贯穿孔3相适配，中心磁片2的一端位于所述贯穿孔3中，外圈磁片1的顶面与中心磁片2的顶面共面；所述外圈磁片1和所述中心磁片2分别由多个纳米晶带材层叠而成且相邻两个纳米晶带材通过绝缘胶粘接，中心磁片2的磁导率小于外圈磁片1的磁导率，所述中心磁片2的纳米晶带材上设有气隙。
本发明的结构/工作原理简述如下：垂直于外圈磁片1的磁力线会诱发中心磁片2产生平行于外圈磁片1的涡流，中心磁片2中气隙的存在则会抑制涡流的产生，从而降低涡流损耗；平行于外圈磁片1的磁力线会诱发外圈磁片1产生垂直于外圈磁片1的涡流，由于外圈磁片1中纳米晶层本身厚度很薄（只有10～20μm），且层与层之间又存在绝缘的高分子胶，外圈磁片1本身就难以产生较大涡流。
从上述描述可知，本发明的有益效果在于：由于外圈磁片与感应涡流的方向垂直，同时层叠纳米晶带材之间存在绝缘胶，外圈磁片的磁导率μ’会很高，其本身并不会产生长自由程涡流，从而使得屏蔽片具备了超高的导磁性能和较低的损耗；同时，虽然磁场在中心磁片面内产生感应涡流，但本发明在中心磁片设有气隙，会抑制长自由程涡流的产生。从而新结构屏蔽片相比于与传统的磁性屏蔽片，在相同的屏蔽性能的条件下，本发明屏蔽片中外圈磁片层叠的纳米晶带材数量更少，而中心磁片恰好镶嵌于线圈中心并不影响模组的厚度，所以有利于屏蔽片的小型化；同时充电效率还有所提升；另外，在屏蔽片生产过程中无需使用传统的“碎磁”工艺，有利于减少屏蔽片的制程，降低屏蔽片的制造成本。
进一步的，所述外圈磁片1的顶面设有胶层5，所述中心磁片2的顶面与所述胶层5相连。
进一步的，所述外圈磁片1由2个或3个纳米晶带材层叠而成；所述中心磁片2由3-12个纳米晶带材层叠而成。
由上述描述可知，外圈磁片中纳米晶带材的层数远少于传统纳米晶屏蔽片中带材层数，有利于屏蔽片的小型化。
进一步的，所述气隙呈网格状。
进一步的，所述外圈磁片1的磁导率大于或等于10000，所述中心磁片2的磁导率为200-6000。
一种无线充电模组用屏蔽片的制备方法，
步骤1：提供纳米晶带材，并对纳米晶带材进行热处理；
步骤2：对经过步骤1的纳米晶带材进行覆胶；
步骤3：将N个纳米晶带材进行层叠，并使相邻两个纳米晶带材粘接，得到第一纳米晶磁片，N为大于2的整数；将M个纳米晶带材进行层叠，并使相邻两个纳米晶带材粘接，得到第二纳米晶磁片，M为大于3的整数且M的数值大于N的数值；
步骤4：对第一纳米晶磁片进行模切轮廓和贯穿孔处理，得到外圈磁片；
对第二纳米晶磁片进行模切轮廓处理以及模切气隙处理，得到中心磁片，其中，所述中心磁片与所述贯穿孔相适配；
步骤5：将中心磁片的一端插入所述贯穿孔中，并使中心磁片的顶面与所述外圈磁片的顶面共面。
进一步的，步骤5之后还包括将中心磁片的顶面与外圈磁片的顶面贴于同一胶层的步骤。
进一步的，所述N为2或3，所述M为3-12中任意一个数值。
进一步的，所述M为3-12中任意一个数值。
进一步的，步骤1中，使用热处理炉对纳米晶带材进行热处理；且在将纳米晶带材投入热处理炉之前还具有将纳米晶带材卷料的步骤。
进一步的，步骤2中采用辊对辊覆胶工艺对纳米晶带材进行覆胶。
实施例一
请参照图1和图2，本发明的实施例一为：一种无线充电模组用屏蔽片，由外圈磁片1和中心磁片2构成，外圈磁片1上设有贯穿孔3，所述中心磁片2与所述贯穿孔3相适配，中心磁片2的一端位于所述贯穿孔3中，外圈磁片1的顶面与中心磁片2的顶面共面；所述外圈磁片1和所述中心磁片2分别由多个纳米晶带材层叠而成且相邻两个纳米晶带材通过绝缘胶粘接，中心磁片2的磁导率小于外圈磁片1的磁导率，所述中心磁片2的纳米晶带材上设有气隙。
图2为本实施例屏蔽片工作原理图，从图中可以看到，磁力线在屏蔽片的作用下已发生偏转。
所述外圈磁片1中相邻两个纳米晶带材通过绝缘高分子胶粘接，所述中心磁片2中相邻两个纳米晶带材通过绝缘高分子胶粘接。
纳米晶带材厚度为10~25μm。
优选的，所述外圈磁片1的顶面设有胶层5，所述中心磁片2的顶面与所述胶层5相连。
详细的，所述外圈磁片1由2个或3个纳米晶带材层叠而成；所述中心磁片2由3-12个纳米晶带材层叠而成。优选的，所述中心磁片2由6-12个纳米晶带材层叠而成。
本实施例中，所述气隙呈网格状。当然，在其他实施例中所述气隙还可以是其他形状的，例如三角框状。
可选的，所述外圈磁片1的磁导率大于或等于10000，所述中心磁片2的磁导率为200-6000。
无线充电模组中，屏蔽片的中心磁片2位于充电线圈4的中空区域，且充电线圈4通过压敏胶粘结在屏蔽片的外圈磁片1上。优选的，充电线圈4的内缘与中心磁片2的外缘相贴合。
实施例二
本发明的实施例二为：一种无线充电模组用屏蔽片的制备方法，
步骤1：提供纳米晶带材，并对纳米晶带材进行热处理；
步骤2：对经过步骤1的纳米晶带材进行覆胶；
步骤3：将N个纳米晶带材进行层叠，并使相邻两个纳米晶带材粘接，得到第一纳米晶磁片，N为大于2的整数；将M个纳米晶带材进行层叠，并使相邻两个纳米晶带材粘接，得到第二纳米晶磁片，M为大于3的整数且M的数值大于N的数值；
步骤4：对第一纳米晶磁片进行模切轮廓和贯穿孔处理，得到外圈磁片；
对第二纳米晶磁片进行模切轮廓处理以及模切气隙处理，得到中心磁片，其中，所述中心磁片与所述贯穿孔相适配；中心磁片的性能要求如下：磁导率μ’为200～2000，磁损耗μ”＜200；
步骤5：将中心磁片的一端插入所述贯穿孔中，并使中心磁片的顶面与所述外圈磁片的顶面共面。
进一步的，步骤5之后还包括将中心磁片的顶面与外圈磁片的顶面贴于同一胶层的步骤。
所述N为2或3，所述M为3-12中任意一个数值。
发明人制造了一批样品，并对样品进行了测试。
纳米晶合金带材牌号：1K107b，厚度为20μm。
使用氮气炉对纳米晶带材进行热处理。热处理具体过程如下：首先让纳米晶带材随炉升温至450～600℃，之后进行2小时的保温，再以500℃/h的速度冷却至250℃出炉。
对热处理后的带材进行单面覆胶；
对一部分单面覆胶的带材进行贴合，并使用模切机进行轮廓冲切及贯穿孔冲切，得到2层及3层第一纳米晶磁片，其参数如表1所示。
表1 第一纳米晶磁片参数表
Figure dest_path_image001
对另一部分单面覆胶带材进行贴合，得到6层、9层、12层第二纳米晶磁片；并通模切机进行轮廓模切及气隙模切，使第二纳米晶磁片形成0.01～0.2mm的网格状气隙，模切后第二纳米晶磁片的磁学参数如表2 所示。
表2 第二纳米晶磁片参数表
Figure dest_path_image002
将第二纳米晶磁片的一端插入第一纳米晶磁片的贯穿孔中，使第一、二纳米晶磁片的顶面共面并使两者顶面通过一胶层连接。
测试：将制备好的样品1~7的磁片组装无线充电模组后，对其进行电性能测试。为了更好的与传统工艺制作的屏蔽片进行对比，发明人还加入了用传统工艺制作的3层、5层纳米晶屏蔽片对应的无线充电模组作为对比样品8和9，样品测试结果如表3所示。
表3 样品测试结果对比表
序号 组合编号 线圈电感L/μH 品质因数Q
Sp1 L3U6 8.35 20.3
Sp2 L3U10 8.36 20.5
Sp3 L3U14 8.36 20.7
Sp4 L3P9 8.37 20.8
Sp5 L3P12 8.39 21
Sp6 L2U10 8.31 20.1
Sp7 L2P12 8.36 20.7
Sp8 3层纳米晶（μ’=1400） 7.9 19.2
Sp9 5层纳米晶（μ’=800） 8.18 18.7
从表3可知，采用本发明的屏蔽片的无线充电模组电感整体高于对比样品 8和9，同时Q值也有比较明显的增加。
利用5W平台对样品1-9进行充电效率测试对比，测试结果如表4所示。
表4 5W平台充电效率测试对比表
Figure dest_path_image003
如表4所示，通过充电效率的对比分析，采用本发明的屏蔽片的无线充电模组充电效率远高于同样层数的采用传统的屏蔽片的无线充电模组，即便与厚度更厚的5层纳米晶磁性材料相比，充电效率也有大约2%左右的提升。
综上所述，本发明提供的无线充电模组用屏蔽片及其制备方法，相比于与传统的磁性屏蔽片，在相同的屏蔽性能的条件下，本发明屏蔽片中外圈磁片层叠的纳米晶带材数量更少，而中心磁片恰好镶嵌于线圈中心并不影响模组的厚度，所以有利于屏蔽片的小型化；同时充电效率还有所提升；另外，在屏蔽片生产过程中无需使用传统的“碎磁”工艺，有利于减少屏蔽片的制程，降低屏蔽片的制造成本。
以上所述仅为本发明的实施例，并非因此限制本发明的专利范围，凡是利用本发明说明书及附图内容所作的等同变换，或直接或间接运用在相关的技术领域，均同理包括在本发明的专利保护范围内。

Claims (10)

  1. 一种无线充电模组用屏蔽片，其特征在于：由外圈磁片和中心磁片构成，外圈磁片上设有贯穿孔，所述中心磁片与所述贯穿孔相适配，中心磁片的一端位于所述贯穿孔中，外圈磁片的顶面与中心磁片的顶面共面；所述外圈磁片和所述中心磁片分别由多个纳米晶带材层叠而成且相邻两个纳米晶带材通过绝缘胶粘接，中心磁片的磁导率小于外圈磁片的磁导率，所述中心磁片的纳米晶带材上设有气隙。
  2. 根据权利要求1所述的无线充电模组用屏蔽片，其特征在于：所述外圈磁片的顶面设有胶层，所述中心磁片的顶面与所述胶层相连。
  3. 根据权利要求1所述的无线充电模组用屏蔽片，其特征在于：所述外圈磁片由2个或3个纳米晶带材层叠而成；所述中心磁片由3-12个纳米晶带材层叠而成。
  4. 根据权利要求1所述的无线充电模组用屏蔽片，其特征在于：所述气隙呈网格状。
  5. 根据权利要求1所述的无线充电模组用屏蔽片，其特征在于：所述外圈磁片的磁导率大于或等于10000，所述中心磁片的磁导率为200-6000。
  6. 一种无线充电模组用屏蔽片的制备方法，其特征在于：
    步骤1：提供纳米晶带材，并对纳米晶带材进行热处理；
    步骤2：对经过步骤1的纳米晶带材进行覆胶；
    步骤3：将N个纳米晶带材进行层叠，并使相邻两个纳米晶带材粘接，得到第一纳米晶磁片，N为大于2的整数；将M个纳米晶带材进行层叠，并使相邻两个纳米晶带材粘接，得到第二纳米晶磁片，M为大于3的整数且M的数值大于N的数值；
    步骤4：对第一纳米晶磁片进行模切轮廓和贯穿孔处理，得到外圈磁片；
    对第二纳米晶磁片进行模切轮廓处理以及模切气隙处理，得到中心磁片，其中，所述中心磁片与所述贯穿孔相适配；
    步骤5：将中心磁片的一端插入所述贯穿孔中，并使中心磁片的顶面与所述外圈磁片的顶面共面。
  7. 根据权利要求6所述的无线充电模组用屏蔽片的制备方法，其特征在于：步骤5之后还包括将中心磁片的顶面与外圈磁片的顶面贴于同一胶层的步骤。
  8. 根据权利要求6所述的无线充电模组用屏蔽片的制备方法，其特征在于：所述N为2或3，所述M为3-12中任意一个数值。
  9. 根据权利要求6所述的无线充电模组用屏蔽片的制备方法，其特征在于：步骤1中，使用热处理炉对纳米晶带材进行热处理；且在将纳米晶带材投入热处理炉之前还具有将纳米晶带材卷料的步骤。
  10. 根据权利要求6所述的无线充电模组用屏蔽片的制备方法，其特征在于：步骤2中采用辊对辊覆胶工艺对纳米晶带材进行覆胶。
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