MAGNETIC ELEMENT FOR WIRELESS POWER TRANSMISSION AND METHOD FOR MANUFACTURING SAME

• US 20140002228A1
• Filed: 03/06/2012
• Published: 01/02/2014
• Est. Priority Date: 03/24/2011
• Status: Active Grant

• Current Assignee: Nitto Denko Corporation
• Original Assignee: Nitto Denko Corporation
• Inventors: Hatanaka, Takezo, Goto, Chisato
• Granted Patent: US 9,251,950 B2
• Time in Patent Office: Days
• US Class Current: 336/200
• CPC Class Codes: H01F 1/15375 using polymers
• CPC Class Codes: H01F 17/043 with two, usually identical or nearly identical parts enclosing completely the coil (pot cores)
• CPC Class Codes: H01F 27/2823 Wires H01F27/2866 takes precedence
• 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 41/02 for manufacturing cores, coils, or magnets H01F41/14 takes precedence; for dynamo-electric machines H02K15/00
• CPC Class Codes: H01F 41/0246 Manufacturing of magnetic circuits by moulding or by pressing powder magnetic cores made by moulding or by pressing powder H01F27/255; soft magnetic particles H01F1/20, H01F1/36
• CPC Class Codes: Y10T 29/4902 Electromagnet, transformer or inductor

Abstract

The purpose of the present invention is to provide: a magnetic element for wireless power transmission, which is capable of feeding power with high power transmission efficiency, while increasing the heat dissipation performance; and a method for manufacturing the magnetic element for wireless power transmission magnetic element for wireless power transmission have configurations that respectively comprise planar coils through which an alternating current passes and magnetic parts which are arranged in parallel in the intervals between the copper wires of the planar coils when viewed in cross section. The magnetic parts comprise an epoxy resin in which iron-based amorphous particles FINEMET® serving as magnetic particles are dispersed, and the magnetic parts are integrated with the planar coils by being bonded to the planar coils in an electrically insulated state by means of the epoxy resin.

Claims

1. A magnetic element for wireless power transmission, which generates an induced electromotive force, comprising:

a conductor portion through which an alternating current flows; and

a magnetic part arranged in parallel to the conductor portion,

wherein the magnetic part includes a resin in which magnetic particles are dispersed, and the conductor portion is at least partially bonded and integrated with the magnetic part, while being electrically insulated therefrom, by the resin.

2. The magnetic element according to claim 1, wherein the resin is a thermosetting resin.

3. The magnetic element according to claim 1, wherein the resin is a thermoplastic resin.

4. The magnetic element according to claim 1, wherein the magnetic particles are soft magnetism particles.

5. The magnetic element according to claim 4, wherein the soft magnetism particles are metal based magnetic particles.

6. The magnetic element according to claim 5, wherein the metal based magnetic particles are amorphous particles.

7. The magnetic element according to claim 1, wherein the magnetic part has a plurality of grooves.

8. A method of manufacturing a magnetic element for wireless power transmission as described in claim 1, comprising:

a magnetic particles dispersing process for dispersing magnetic particles in a resin;

a B-staging process for heating the resin in which the magnetic particles are dispersed so as to cause the resin in a B-stage;

a pressuring process for applying a pressure to a stack of conductor portions and the resin in the B-stage; and

a curing process for curing the resin in the B-stage which is bonded with the conductor portions.

9. The method according to claim 8, wherein, in the pressuring process,

a plurality of grooves are formed to the resin in the B-stage.

10. The method according to claim 8, wherein, in the pressuring process,

a conductive formed member having an interval between its conductor portions adjacent to each other is stacked with the resin in the B-stage, and is bonded by applying a pressure.

11. The method according to claim 8, wherein the resin is a thermosetting resin, and

in the curing process, the thermosetting resin in the B-stage is cured by a thermal treatment.

12. The method according to claim 8, wherein the resin is a thermoplastic resin, and

in the curing process, the thermoplastic resin softened by a thermal treatment is supplied between the conductor portions and is fixed by solidifying the resin by cooling.