Multi wireless charging apparatus and method for manufacturing the same

• US 9,318,899 B2
• Filed: 12/28/2012
• Issued: 04/19/2016
• Est. Priority Date: 12/30/2011
• Status: Active Grant

• Current Assignee: Wit Co., Ltd.
• Original Assignee: Samsung Electro-Mechanics Co., Ltd. (Samsung Group)
• Inventors: Yoon, Young Seok, Yoon, Jung Ho
• Primary Examiner(s): Nguyen, Nha
• Application Number:
  US13/729,826
• Publication Number:
  US 20130169222A1
• Time in Patent Office: 1,208 Days
• US Class Current: 1/1
• CPC Class Codes: H01F 38/14 Inductive couplings for wireless supply or distribution of electric power using inductive coupling H02J50/10
• 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 50/402 the two or more transmitting or the two or more receiving devices being integrated in the same unit, e.g. power mats with several coils or antennas with several sub-antennas
• CPC Class Codes: H02J 50/70 involving the reduction of electric, magnetic or electromagnetic leakage fields
• CPC Class Codes: H02J 50/90 involving detection or optimisation of position, e.g. alignment
• CPC Class Codes: H02J 7/00 Circuit arrangements for charging or depolarising batteries or for supplying loads from batteries
• CPC Class Codes: H02J 7/0042 characterised by the mechanical construction
• CPC Class Codes: Y10T 156/1002 with permanent bending or reshaping or surface deformation of self sustaining lamina

Abstract

Disclosed herein are a multi wireless charging apparatus and a method for manufacturing the same. The multi wireless charging apparatus includes: a control unit wholly controlling a multi wireless charging process; and a plurality of wireless charging units electrically connected with the control and deformed into a roll form by being bonded so as to a plurality of interlayer voids at the time of laminating a plurality of flexible substrates. By this configuration, the multi wireless charging apparatus can be rolled up in a roll form while having a slim thickness and therefore, can be conveniently carried.

Claims

1. A multi wireless charging apparatus, comprising:

a controller wholly controlling a multi wireless charging process; and

a plurality of wireless charging units electrically connected with the control and deformed into a roll form by having layers bonded together at which the layers are electrically connected with each other so as to be provided with a plurality of interlayer voids at the time of laminating a plurality of flexible substrates, each of the wireless charging units comprising

a plurality of double-sided flexible copper clad laminates (FCCLs) having circuit layers formed on upper surfaces or lower surfaces thereof,

an adhesive layer in which an adhesive is separately disposed into a corresponding area to be provided with the plurality of interlayer voids by bonding only portions at which layers are electrically connected with each other at the time of laminating the plurality of double-sided FCCLs, and

a plurality of conductive via holes formed so as to electrically interlayer-connect the portions bonded by the adhesive on the plurality of double-sided FCCLs.

2. The multi wireless charging apparatus as set forth in claim 1, wherein each of the wireless charging units is further provided with shielding layers made of a flexible conductive material and formed on lower surfaces of the plurality of flexible substrates so as to shield electromagnetic field.

3. The multi wireless charging apparatus as set forth in claim 2, wherein the flexible conductive material is any one of a conductive paste, conductive coating, and a conductive sheet.

4. The multi wireless charging apparatus as set forth in claim 1, wherein the adhesive is a flexible adhesive.

5. The multi wireless charging apparatus as set forth in claim 4, wherein the flexible adhesive is a prepreg in which a semi hardening resin is impregnated in the flexible adhesive.

6. The multi wireless charging apparatus as set forth in claim 1, wherein each of the circuit layers includes:

coil patterns formed in a continuous closed loop and having first ends disposed inside the closed loop and second ends disposed outside the closed loop;

first electrode patterns spaced apart from the first ends and disposed outside the closed loop of the coil patterns; and

second electrode patterns correspondingly spaced apart from the first electrode patterns and disposed outside the closed loop of the coil patterns, and

wherein the second ends are integrally formed with the second electrode patterns.

7. The multi wireless charging apparatus as set forth in claim 6, wherein the adhesive layer bonds the plurality of double-sided FCCLs by disposing the adhesive so as to correspond to a portion at which the first ends, the first electrode patterns, and the second electrode patterns integrally formed with the second ends that are formed on the plurality of double-sided FCCLs, respectively, are disposed, for interlayer connection of the plurality of double-sided FCCLs.

8. The multi wireless charging apparatus as set forth in claim 7, wherein each of the wireless charging units further includes:

a first conductive via hole formed to electrically interlayer-connect the first ends of each layer bonded by the adhesive on the plurality of double-sided FCCLs;

a second conductive via hole formed to electrically interlayer-connect the first electrode patterns of each layer bonded by the adhesive on the plurality of double-sided FCCLs;

a third conductive via hole formed to electrically interlayer-connect the second electrode patterns integrally formed with the second ends bonded by the adhesive on the plurality of double-sided FCCLs; and

a wiring layer formed by crossing the first and second conductive via holes so as to connect between the first and second conductive via holes on an outer layer of the uppermost double-sided FCCL among the plurality of double-sided FCCLs.

9. The multi wireless charging apparatus as set forth in claim 8, wherein each of the wireless charging units further includes a cover layer covering an upper surface of the uppermost double-sided FCCL or a lower surface of the lowest double-sided FCCL among the plurality of double-sided FCCLs.

10. The multi wireless charging apparatus as set forth in claim 9, wherein the cover layer is an insulating layer made of a flexible material that is bonded by a flexible adhesive.

11. A method for manufacturing a multi wireless charging apparatus, comprising:

forming a plurality of wireless charging units deformed into a roll form by having layers bonded together at which the layers are electrically connected with each other so as to be provided with a plurality of interlayer voids at the time of laminating a plurality of flexible substrates; and

forming a controller electrically connected with the plurality of wireless charging units to wholly control multi charging of the plurality of wireless charging units, wherein the forming of the plurality of wireless charging units comprises

preparing a plurality of double-sided FCCLs having a circuit layer formed on an upper surface or a lower surface thereof,

compressing the plurality of double-sided FCCLs using an adhesive separately disposed into a corresponding area as an intermediate medium to be provided with the plurality of interlayer voids by bonding only portions at which layer are electrically connected with each other at the time of laminating the plurality of double sided FCCLs,

forming a plurality of conductive via holes for electrically interlayer-connecting portions bonded by the adhesive on the plurality of compressed double-sided FCCLs and forming a wiring layer on an outer layer of an uppermost double-sided FCCL among the plurality of double-sided FCCLs so that some of the conductive via holes are electrically connected with each other, and

forming a cover layer covering outer surfaces of the plurality of the double-sided FCCLs.

12. The method as set forth in claim 11, wherein in the preparing the plurality of double-sided FCCLs, each of the circuit layers is formed by:

forming coil patterns formed in a continuous closed loop and having first ends disposed inside the closed loop and second ends disposed outside the closed loop;

forming first electrode patterns spaced apart from the first ends and disposed outside the closed loop of the coil patterns; and

forming second electrode patterns correspondingly spaced apart from the first electrode patterns and disposed outside the closed loop of the coil patterns, and

wherein the second ends are integrally formed with the second electrode patterns.

13. The method as set forth in claim 12, wherein in the compressing the plurality of double-sided FCCLs, the adhesive layer is formed by:

disposing the adhesive so as to correspond to a portion at which the first ends, the first electrode patterns, and the second electrode patterns integrally formed with the second ends that are formed on the plurality of double-sided FCCLs, respectively, are disposed, for interlayer connection of the plurality of double-sided FCCLs; and

compressing and adhering the plurality of double-sided FCCLs and the adhesive.

14. The method as set forth in claim 13, wherein the forming the plurality of conductive via holes includes:

forming a first conductive via hole for electrically interlayer-connecting the first ends of each layer bonded by the adhesive on the plurality of double-sided FCCLs;

forming a second conductive via hole for electrically interlayer-connecting the first electrode patterns of each layer bonded by the adhesive on the plurality of double-sided FCCLs;

forming a third conductive via hole for electrically interlayer-connecting the second electrode patterns integrally formed with the second ends bonded by the adhesive on the plurality of double-sided FCCLs; and

forming a wiring layer crossing the first and second conductive via holes so as to connect between the first and second conductive via holes on a part of the upper surface of the uppermost double-sided FCCL among the plurality of double-sided FCCLs.

15. The method as set forth in claim 14, wherein the forming the cover layer includes:

forming a first insulating layer made of a flexible insulating material so as to protect the circuit formed on the upper surface of the uppermost double-sided FCCL among the plurality of double-sided FCCLs and prevent the circuit from being oxidized;

forming a second insulating layer made of a flexible insulating material so as to protect the circuit formed on the lower surface of the lowest double-sided FCCL among the plurality of double-sided FCCLs and prevent the circuit from being oxidized; and

forming a shielding layer made of a flexible conductive material on an outer surface of the second insulating layer so as to shield electromagnetic field for each area of the wireless charging part.

16. The method as set forth in claim 15, wherein the flexible conductive material is any one of a conductive paste, conductive coating, and a conductive sheet.

17. A multi wireless charging apparatus, comprising:

a controller wholly controlling a multi wireless charging process; and

a plurality of wireless charging units electrically connected with the control and deformed into a roll form by being bonded to be provided with a plurality of interlayer voids at the time of laminating a plurality of flexible substrates, each of the wireless charging units including

a plurality of double-sided flexible copper clad laminates (FCCL) having circuit layers formed on upper surfaces or lower surfaces thereof,

an adhesive layer in which an adhesive is separately disposed into the corresponding area to be provided with a plurality of interlayer voids by bonding only portions at which layers are electrically connected with each other at the time of laminating the plurality of double-sided FCCLs, each of the circuit layers including

coil patterns formed in a continuous closed loop and having first ends disposed inside the closed loop and second ends disposed outside the closed loop,

first electrode patterns spaced apart from the first ends and disposed outside the closed loop of the coil patterns, and

second electrode patterns correspondingly spaced apart from the first electrode patterns and disposed outside the closed loop of the coil patterns, and wherein the second ends are integrally formed with the second electrode patterns,

wherein the adhesive layer bonds the plurality of double-sided FCCLs by disposing the adhesive so as to correspond to a portion at which the first ends, the first electrode patterns, and the second electrode patterns integrally formed with the second ends that are formed on the plurality of double-sided FCCLs, respectively, are disposed, for interlayer connection of the plurality of double-sided FCCLs, and

each of the wireless charging units further including

a first conductive via hole formed to electrically interlayer-connect the first ends of each layer bonded by the adhesive on the plurality of double-sided FCCLs,

a second conductive via hole formed to electrically interlayer-connect the first electrode patterns of each layer bonded by the adhesive on the plurality of double-sided FCCLs,

a third conductive via hole formed to electrically interlayer-connect the second electrode patterns integrally formed with the second ends bonded by the adhesive on the plurality of double-sided FCCLs, and

a wiring layer formed by crossing the first and second conductive via holes so as to connect between the first and second conductive via holes on an outer layer of the uppermost double-sided FCCL among the plurality of double-sided FCCLs.