Flux concentrator and method of making a magnetic flux concentrator
First Claim
1. A permanently laminated flux concentrator assembly comprising:
- a flux concentrator having a thickness, a top surface, and a bottom surface; and
a coil embedded in said flux concentrator, wherein one side of said coil is flush with said top surface of said flux concentrator forming an exposed side and another side of said coil is embedded within said thickness of said flux concentrator forming an unexposed side, wherein said coil is capable of inductive coupling on said exposed side and is incapable of inductive coupling on said unexposed side;
wherein said flux concentrator includes scoring to influence where said flux concentrator breaks in response to flexing; and
a laminate adhesively and permanently secured to said flux concentrator forming a permanent bond between said laminate and said flux concentrator, wherein said laminate and said permanent bond hold together pieces of said flux concentrator that are broken at or near at least a portion of said scoring in response to flexing, wherein breaking said laminated flux concentrator does not significantly affect the magnetic properties of said laminated flux concentrator.
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Accused Products
Abstract
A flux concentrator and method for manufacturing a flux concentrator is provided. The method can include combining powdered soft magnetic material, a binder, a solvent, a internal lubricant; mixing the materials to create a mixture, evaporating the solvent from the mixture, molding the mixture to form a flux concentrator, and curing the flux concentrator. The flux concentrator may be laminated and broken into multiple pieces, which makes the flux concentrator more flexible. Breaking the flux concentrator does not significantly affect the magnetic properties. Since the permeability of the binder is very similar to that of air, adding tiny air gaps between the fractions is not significantly different than adding more binder.
175 Citations
19 Claims
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1. A permanently laminated flux concentrator assembly comprising:
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a flux concentrator having a thickness, a top surface, and a bottom surface; and a coil embedded in said flux concentrator, wherein one side of said coil is flush with said top surface of said flux concentrator forming an exposed side and another side of said coil is embedded within said thickness of said flux concentrator forming an unexposed side, wherein said coil is capable of inductive coupling on said exposed side and is incapable of inductive coupling on said unexposed side; wherein said flux concentrator includes scoring to influence where said flux concentrator breaks in response to flexing; and a laminate adhesively and permanently secured to said flux concentrator forming a permanent bond between said laminate and said flux concentrator, wherein said laminate and said permanent bond hold together pieces of said flux concentrator that are broken at or near at least a portion of said scoring in response to flexing, wherein breaking said laminated flux concentrator does not significantly affect the magnetic properties of said laminated flux concentrator. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9)
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10. A flexible flux concentrator assembly comprising:
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a flux concentrator having a thickness and a surface; wherein said flux concentrator includes scoring to influence where said flux concentrator breaks in response to flexing; a laminate adhesively and permanently secured to at least a portion of said surface of said flux concentrator forming a permanent bond between said laminate and said at least a portion of said surface of said flux concentrator; wherein in response to bending said flexible flux concentrator
1) said flux concentrator is capable of being broken into a plurality of pieces with air gaps therebetween, wherein, in response to breaking said flexible flux concentrator at or near at least a portion of said scoring, said laminate and said permanent bond hold said plurality of pieces together such that said air gaps do not significantly affect the magnetic properties of said flux concentrator; and
2) said laminate remains permanently and adhesively secured to said at least said portion of said surface of said flux concentrator. - View Dependent Claims (11, 12, 13, 14, 15, 16, 17, 18, 19)
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Specification