Noncontact power-transmission coil, portable terminal and terminal charging device, planar coil magnetic layer formation device, and magnetic layer formation method

• US 20080164844A1
• Filed: 01/07/2008
• Published: 07/10/2008
• Est. Priority Date: 01/09/2007
• Status: Active Grant

• Current Assignee: Seiko Epson Corporation (Seiko Group), Sony Ericsson Mobile Communications Japan Incorporated (Sony Group Corp.)
• Original Assignee: Seiko Epson Corporation (Seiko Group), Sony Ericsson Mobile Communications Japan Incorporated (Sony Group Corp.)
• Inventors: Suzuki, Katsuya, Yamazaki, Manabu, Onishi, Kota, Jin, Mikimoto, Kato, Hiroshi, Kamijo, Takahiro, Kondo, Yoichiro, Suzuki, Kuniharu, Yoda, Kentaro, Sogabe, Haruhiko
• Granted Patent: US 8,072,304 B2
• Time in Patent Office: Days
• US Class Current: 320/114
• CPC Class Codes: H01F 27/24 Magnetic cores
• CPC Class Codes: H01F 27/2871 Pancake coils
• CPC Class Codes: H01F 38/14 Inductive couplings for wireless supply or distribution of electric power using inductive coupling H02J50/10
• CPC Class Codes: H01F 41/16 the magnetic material being applied in the form of particles, e.g. by serigraphy , to form thick magnetic films or precursors therefor H01F41/18 -H01F41/24 take precedence
• CPC Class Codes: H01F 5/003 Printed circuit coils
• CPC Class Codes: H02J 50/005 Mechanical details of housing or structure aiming to accommodate the power transfer means, e.g. mechanical integration of coils, antennas or transducers into emitting or receiving devices
• CPC Class Codes: H02J 50/10 using inductive coupling
• CPC Class Codes: H02J 50/60 responsive to the presence of foreign objects, e.g. detection of living beings
• CPC Class Codes: H02J 7/00045 Authentication, i.e. circuits for checking compatibility between one component, e.g. a battery or a battery charger, and another component, e.g. a power source
• CPC Class Codes: Y10T 29/49073 by assembling coil and core
• CPC Class Codes: Y10T 29/53165 Magnetic memory device

Abstract

A noncontact power-transmission coil is provided. The noncontact power-transmission coil includes a planar coil and a magnetic layer. The planar coil is formed by winding a linear conductor in a spiral shape substantially in a single plane. The magnetic layer is formed by applying a liquid-form magnetic solution in which magnetic particles are mixed with a binder solvent, so as to cover one planar portion of the planar coil and a side-face portion of the planar coil.

Claims

1. A noncontact power-transmission coil, comprising:

a planar coil, formed by winding a linear conductor in a spiral shape substantially in a single plane; and

,

a magnetic layer, formed by applying a liquid-form magnetic solution in which magnetic particles are mixed with a binder solvent, so as to cover one planar portion of the planar coil and a side-face portion of the planar coil.

2. A noncontact power-transmission coil according to claim 1, wherein

the planar coil is formed by winding the linear conductor, including either single wire or twisted wire, in a spiral shape substantially in the same plane.

3. A noncontact power-transmission coil according to claim 2, further comprising

a flexible printed-circuit board on which are formed first and second external connection terminal portions, a first contact portion connected to an inner periphery-side end portion of the linear conductor wound into a spiral shape, a second contact portion connected to an outer periphery-side end portion of the linear conductor wound into a spiral shape, a first conductor pattern connecting the first contact portion and the first external connection terminal portion, and a second conductor pattern connecting the second contact portion and the second external connection terminal portion, wherein

the other planar portion of the planar coil is affixed to the surface of the flexible printed-circuit board.

4. A noncontact power-transmission coil according to claim 1,

wherein the planar coil has a plurality of laminated flexible printed-circuit boards, on each of which is formed a spiral-shape conductor pattern, and which are formed into a shape which substantially matches the outer-perimeter shape of the spiral-shape conductor pattern, a first through-hole which electrically connects inner-periphery pattern end portions of the conductor patterns of each layer of the laminated flexible printed-circuit boards, and a second through-hole which electrically connects outer-periphery pattern end portions of the conductor patterns of each layer of the laminated flexible printed-circuit boards, and

wherein one flexible printed-circuit board layer among the layers of the flexible printed-circuit board has first and second external connection terminal portions, a first conductor pattern which electrically connects the first through-hole with the first external connection terminal portion, and a second conductor pattern which electrically connects the second through-hole with the second external connection terminal portion.

5. A noncontact power-transmission coil according to claim 1, wherein

the planar coil has a central hole in an inner-periphery portion of the linear conductor wound into a spiral shape and has the magnetic layer formed by applying the magnetic solution so as to fill the central hole of the planar coil.

6. A portable terminal, comprising:

a noncontact power-transmission coil, having a rechargeable battery, a planar coil formed by winding a linear conductor in a spiral shape in substantially the same plane, and a magnetic layer formed by applying a liquid-form magnetic solution, in which magnetic particles are mixed with a binder solvent, so as to cover one planar portion of the planar coil and a side-face portion of the planar coil; and

,

a charging control circuit, which executes control to charge the rechargeable battery with power received via the noncontact power-transmission coil.

7. A portable terminal according to claim 6, wherein

the planar coil of the noncontact power-transmission coil is formed by winding the linear conductor, including a single wire or twisted wire, in a spiral shape in substantially the same plane.

8. A portable terminal according to claim 7,

wherein the noncontact power-transmission coil has a flexible printed-circuit board, on which are formed first and second external connection terminal portions, a first contact portion connected to an inner periphery-side end portion of the linear conductor wound into a spiral shape, a second contact portion connected to an outer periphery-side end portion of the linear conductor wound into a spiral shape, a first conductor pattern connecting the first contact portion and the first external connection terminal portion, and a second conductor pattern connecting the second contact portion and the second external connection terminal portion, and

wherein the other planar portion of the planar coil is affixed to the surface of the flexible printed-circuit board.

9. A portable terminal according to claim 6,

wherein the planar coil of the noncontact power-transmission coil has a plurality of laminated flexible printed-circuit boards, on each of which is formed a spiral-shape conductor pattern, and which are formed into a shape which substantially matches the outer-perimeter shape of the spiral-shape conductor pattern, a first through-hole which electrically connects inner-periphery pattern end portions of the conductor patterns of each layer of the laminated flexible printed-circuit boards, and a second through-hole which electrically connects outer-periphery pattern end portions of the conductor patterns of each layer of the laminated flexible printed-circuit boards, and

wherein one flexible printed-circuit board layer among the layers of the flexible printed-circuit board has first and second external connection terminal portions, a first conductor pattern which electrically connects the first through-hole with the first external connection terminal portion, and a second conductor pattern which connects the second through-hole with the second external connection terminal portion.

10. A portable terminal according to claim 6, wherein

the planar coil of the noncontact power-transmission coil has a central hole in an inner-periphery portion of the linear conductor wound into a spiral shape, and having the magnetic layer formed by applying the magnetic solution so as to fill the central hole of the planar coil.

11. A terminal charging device, comprising:

a terminal mounting base, on which a predetermined portable terminal including a rechargeable battery is mounted;

a noncontact power-transmission coil, having a planar coil, formed by winding a linear conductor in a spiral shape substantially in the same plane, and a magnetic layer formed by applying a liquid-form magnetic solution, in which magnetic particles are mixed into a binder solvent, so as to cover one planar portion of the planar coil and a side-face portion of the planar coil, and using electromagnetic induction with a coil installed in the predetermined portable terminal to charge the rechargeable battery of the portable terminal in a noncontact manner; and

a power supply control unit which controls power supply to the noncontact power-transmission coil.

12. A terminal charging device according to claim 11, wherein

the planar coil of the noncontact power-transmission coil is formed by winding a linear conductor, comprising a single wire or twisted wire, in a spiral shape in substantially the same plane.

13. A terminal charging device according to claim 12,

wherein the noncontact power-transmission coil has a flexible printed-circuit board, on which are formed first and second external connection terminal portions, a first contact portion connected to an inner periphery-side end portion of the linear conductor wound into a spiral shape, a second contact portion connected to an outer periphery-side end portion of the linear conductor wound into a spiral shape, a first conductor pattern connecting the first contact portion and the first external connection terminal portion, and a second conductor pattern connecting the second contact portion and the second external connection terminal portion, and

wherein the other planar portion of the planar coil is affixed to the surface of the flexible printed-circuit board.

14. A terminal charging device according to claim 11,

wherein the planar coil of the noncontact power-transmission coil has a plurality of laminated flexible printed-circuit boards, on each of which is formed a spiral-shape conductor pattern, and which are formed into a shape which substantially matches the outer-perimeter shape of the spiral-shape conductor pattern, a first through-hole which electrically connects inner-periphery pattern end portions of the conductor patterns of each layer of the laminated flexible printed-circuit boards, and a second through-hole which electrically connects outer-periphery pattern end portions of the conductor patterns of each layer of the laminated flexible printed-circuit boards, and

wherein one flexible printed-circuit board layer among the layers of the flexible printed-circuit board has first and second external connection terminal portions, a first conductor pattern which electrically connects the first through-hole with the first external connection terminal portion, and a second conductor pattern which connects the second through-hole with the second external connection terminal portion.

15. A terminal charging device according to claim 11, wherein

the planar coil of the noncontact power-transmission coil has a central hole in an inner-periphery portion of the linear conductor wound into a spiral shape, and having the magnetic layer formed by applying the magnetic solution so as to fill the central hole of the planar coil.

16. A planar coil magnetic layer formation device, comprising:

a planar coil-fitting portion, having a bottom-face portion on which is placed the other planar-portion side of a planar coil formed by winding a linear conductor in a spiral shape substantially in the same plane, and an inner-wall portion which is larger than at least the outer-perimeter diameter of the planar coil, and in which is formed a depressed shape which is at least deeper than the thickness of the planar coil; and

,

a magnetic solution application portion, which, in a state in which the planar coil is fitted into the planar coil-fitting portion, by applying from an aperture portion of the planar coil-fitting portion a magnetic solution in liquid form in which magnetic particles are mixed into a binder solvent, forms a magnetic layer covering one planar portion of the planar coil and a side-face portion of the planar coil.

17. A planar coil magnetic layer formation device according to claim 16, further comprising

a positioning protruding portion, to determine the fitting position of the planar coil, in the bottom-face portion of the planar coil-fitting portion.

18. A planar coil magnetic layer formation device according to claim 16, further comprising

a compression-molding mechanism which performs compression of the magnetic solution applied by the magnetic solution application portion so as to cover one planar portion of the planar coil and the side-face portion of the planar coil.

19. A planar coil magnetic layer formation device according to claim 16, further comprising

a planar coil ejection portion, on the bottom-face portion of the planar coil-fitting portion, which ejects and removes a planar coil fitted into the planar coil-fitting portion from the bottom-face portion side.

20. A planar coil magnetic layer formation device according to claim 19, further comprising

a drying mechanism which dries the magnetic solution applied onto the planar coil removed from the planar coil-fitting portion.

21. A planar coil magnetic layer formation device according to claim 16, wherein

the magnetic solution application portion has a magnetic solution injection mechanism which injects the magnetic solution from an aperture of the planar coil-fitting portion.

22. A planar coil magnetic layer formation device according to claim 16, wherein

the magnetic solution application portion has a porous screen in which are opened numerous minute holes, a magnetic solution dispenser which dispenses the magnetic solution onto the porous screen positioned so as to cover an aperture portion of the planar coil-fitting portion, and a blade mechanism which moves over the porous screen and causes magnetic solution dispensed onto the porous screen to be pressed into the minute holes and to drip from the minute holes onto the planar coil-fitting portion.

23. A planar coil magnetic layer formation device according to claim 16, wherein

the concentration of the magnetic particles and binder solvent of the magnetic solution is a concentration such that the relative permeability is 50 or higher.

24. A planar coil magnetic layer formation method, comprising the steps of:

fitting a planar coil, formed by winding a linear conductor in a spiral shape substantially in the same plane, into a planar coil-fitting portion, having a bottom-face portion on which one planar portion side of the planar coil is placed and an inner-wall portion which is larger than at least the outer-perimeter diameter of the planar coil, and in which is formed a depressed shape which is at least deeper than the thickness of the planar coil; and

,

forming a magnetic layer which covers one planar portion of the planar coil and a side-face portion of the planar coil, by applying, in a state in which the planar coil is fitted into the planar coil-fitting portion, a liquid-form magnetic solution in which magnetic particles are mixed into a binder solvent, from an aperture in the planar coil-fitting portion, using a magnetic solution application portion.

25. A planar coil magnetic layer formation method according to claim 24, further comprising the step of

compressing, using a compression-molding mechanism, the magnetic solution applied by the magnetic solution application portion so as to cover one planar portion of the planar coil and the side-face portion of the planar coil.

26. A planar coil magnetic layer formation method according to claim 24, further comprising the step of

ejecting and removing the planar coil, in the state of having the magnetic solution applied, from the side of the bottom-face portion of the planar coil-fitting portion, using a planar coil ejection portion provided on the side of the bottom-face portion of the planar coil-fitting portion.

27. A planar coil magnetic layer formation method according to claim 26, further comprising the step of

drying, using a drying mechanism, the magnetic solution applied onto a planar coil removed from the planar coil-fitting portion.

28. A planar coil magnetic layer formation method according to claim 24, wherein

the process of applying a magnetic solution includes a process of injecting, using a magnetic solution injection mechanism, the magnetic solution from an aperture portion of the planar coil-fitting portion.

29. A planar coil magnetic layer formation method according to claim 24, wherein

the process of applying the magnetic solution has a process of positioning a porous screen in which are opened numerous minute holes over an aperture portion of the planar coil-fitting portion, a process of dispensing the magnetic solution from a magnetic solution dispenser into the porous screen, and a process of moving a blade mechanism over the porous screen, causing the magnetic solution dispensed onto the porous screen to be pressed into the minute holes and to drip from the minute holes into the planar coil-fitting portion.

30. A planar coil magnetic layer formation method according to claim 24, wherein

the concentration of the magnetic particles and binder solvent of the magnetic solution is a concentration such that the relative permeability is 50 or higher.