USOO8922160B2
`
`(12) United States Patent
`Inoue
`
`(10) Patent No.:
`(45) Date of Patent:
`
`US 8,922,160 B2
`Dec. 30, 2014
`
`(54) NON-CONTACT TYPE POWER RECEIVING
`APPARATUS, ELECTRONIC EQUIPMENT
`AND CHARGING SYSTEMUSING THE
`POWER RECEIVINGAPPARATUS
`
`(58) Field of Classification Search
`CPC ........................................................ HO2J 7/O25
`USPC .......................................................... 32Of 108
`See application file for complete search history.
`
`(*) Notice:
`
`(75) Inventor: Tetsuo Inoue, Yokohama (JP)
`(73) Assignees: Kabushiki Kaisha Toshiba, Tokyo (JP);
`Toshiba Materials Co., Ltd.,
`Yokohama-shi (JP)
`Subject to any disclaimer, the term of this
`patent is extended or adjusted under 35
`U.S.C. 154(b) by 1076 days.
`12/674,347
`Aug. 20, 2008
`
`(21) Appl. No.:
`(22) PCT Filed:
`(86). PCT No.:
`S371 (c)(1),
`(2), (4) Date:
`Feb. 19, 2010
`(87) PCT Pub. No.: WO2009/025279
`PCT Pub. Date: Feb. 26, 2009
`
`PCT/UP2008/064787
`
`(65)
`
`(30)
`
`Prior Publication Data
`US 2011/0210696A1
`Sep. 1, 2011
`Foreign Application Priority Data
`
`Aug. 21, 2007 (JP) ................................. 2007-214503
`
`(2006.01)
`(2006.01)
`(2006.01)
`(2006.01)
`(2006.01)
`
`(51) Int. Cl.
`H02. 7/00
`HOIF 38/14
`HOIF 27/36
`HOIF 27/28
`HO2.J.5/OO
`(52) U.S. Cl.
`CPC .............. H0IF 38/14 (2013.01); H01F 27/365
`(2013.01); HOIF 27/2804 (2013.01); HOIF
`2038/143 (2013.01); H02.J5/005 (2013.01)
`USPC ........................................... 320/108; 336/200
`
`(56)
`
`References Cited
`
`U.S. PATENT DOCUMENTS
`
`4,640,871 A * 2/1987 Hayashi et al. ............... 428,611
`6.593,841 B1* 7/2003 Mizoguchi et al. ........... 336,200
`(Continued)
`
`FOREIGN PATENT DOCUMENTS
`
`JP
`JP
`
`3, 1987
`6236512
`3, 1996
`8 79976
`(Continued)
`Primary Examiner — Edward Tso
`Assistant Examiner — Johali Torres Ruiz
`(74) Attorney,
`Agent,
`or
`Firm — Oblon,
`McClelland, Maier & Neustadt, L.L.P.
`
`Spivak,
`
`ABSTRACT
`(57)
`A non-contact type power receiving apparatus including: a
`power receiving coil having a spiral coil; a rectifier; a second
`ary battery; an electronic device operated by being supplied
`with direct voltage from the secondary battery, wherein a
`composite magnetic body is provided to at least one portion
`between the secondary battery and the spiral coil, and a por
`tion between the electronic device and the spiral coil. The
`composite magnetic body includes at least first and other
`layers of magnetic sheets through an insulating layer in which
`when a relative magnetic permeability of the first magnetic
`sheet provided to a side of the spiral coil is ud, a thickness of
`the first magnetic sheet is tu, an average relative magnetic
`permeability of the other magnetic sheets other than the first
`magnetic sheet is Lu, and a total thickness of the other mag
`netic sheets is tu, the composite magnetic body satisfies the
`following relations: ud-tas 60mm; and Lutual 100 mm.
`15 Claims, 3 Drawing Sheets
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`14
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`4-9-5 -
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`2
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`16
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`11
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`1 -
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`US 8,922,160 B2
`Page 2
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`(56)
`
`References Cited
`
`FOREIGN PATENT DOCUMENTS
`
`U.S. PATENT DOCUMENTS
`
`6,603,382 B1* 8/2003 Komai et al. ................. 336,200
`2006, 0083931 A1* 4, 2006 Wadle et al.
`428,432
`2007/0230.042 A1* 10/2007 Fujiwara ....................... 360,123
`2008/0198560 A1* 8/2008 Fujiwara et al. .............. 361/728
`2008, 0211455 A1* 9, 2008 Park et al. ...
`320, 108
`2008, O246571 A1* 10, 2008 Guenther ...................... 335/.297
`
`
`
`JP
`JP
`JP
`WO
`WO
`
`11 176677
`200091113
`2003 257751
`2007 080820
`2007 111019
`
`7, 1999
`3, 2000
`9, 2003
`7/2007
`10/2007
`
`* cited by examiner
`
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`U.S. Patent
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`Dec. 30, 2014
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`U.S. Patent
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`Dec. 30, 2014
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`Sheet 2 of 3
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`US 8,922,160 B2
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`U.S. Patent
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`Dec. 30, 2014
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`Sheet 3 of 3
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`US 8,922,160 B2
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`1.
`NON-CONTACT TYPE POWER RECEIVING
`APPARATUS, ELECTRONIC EQUIPMENT
`AND CHARGING SYSTEMUSING THE
`POWER RECEIVINGAPPARATUS
`
`TECHNICAL FIELD
`
`The present invention relates to a non-contact (contactless)
`type power receiving apparatus, an electronic equipment
`(electronic apparatus) and a charging system (battery charg
`ing system) using the non-contact type power receiving appa
`ratus that are capable of performing a non-contact power
`charging in various electronic equipments such as cellular
`phone, video camera and so on.
`
`BACKGROUND ART
`
`In recent years, a development of handhold communica
`tion gadgets is remarkable. Especially, downsizing and reduc
`tion in weight of mobile phones have advanced. Further, with
`respect to also various electronic equipments such as video
`camera (handy camera or the like), codeless phone, lap-top
`personal computer (notebook type personal computer) other
`than the mobile phone, such the downsizing and reduction in
`weight have been also advanced.
`Since these electronic equipments are provided with a sec
`ondary battery to an electronic equipment body, the electronic
`equipments can be available without plugging in, so that a
`portability and convenience have been greatly improved. At
`the present time, a capacity of the secondary is limited to
`Some extent, so that the secondary battery is necessary to be
`performed with a power-charging operation at least once
`every several days to several weeks.
`As a power charging method, there are two types of charg
`ing methods: a contact-type charging system; and a non
`contact type charging system. The contact-type charging sys
`tem is a system in which an electrode of a power receiving
`apparatus and an electrode of a power Supplying apparatus are
`directly contacted to each other thereby to perform the power
`charging. The contact-type charging system has a simple
`structure for constituting the apparatus, so that the contact
`type charging system has been generally adopted in wide
`application field.
`However, in accordance with the progress of the downsiz
`ing and reduction in weight of the electronic equipments in
`recent years, there has been posed problems such that a
`weight of each electronic equipments is reduced, so that a
`contact pressure between the electrode of the power receiving
`apparatus and the electrode of the power Supplying apparatus
`becomes insufficient thereby to cause a charging defect
`(charging fault). Further, the secondary batter has a small
`resistance to heat, so that it is necessary to avoid a temperature
`rise of the secondary battery, and a circuit design requires to
`be carefully performed so as not to cause an over discharge
`and an overcharge. In order to cope with these problems, the
`non-contact type charging system has been reviewed in these
`days.
`The non-contact type charging system is a power charging
`system utilizing an electromagnetic induction caused by coils
`provided to both the power receiving apparatus and the power
`Supplying apparatus. In this type of the charging system, due
`to the non-contact type, there is no need to pay attention to the
`contact pressure between the electrodes of the two appara
`tuses. Further, it is unnecessary to pay attention to the contact
`pressure, so that a stable charging Voltage can be supplied
`without being influenced by the contacting state of the elec
`trodes of the apparatuses.
`
`2
`The conventional non-contact type charging system has
`been used for electronic equipments such as electric tooth
`brush, electric shaver or the like that are driven by a low power
`consumption and require a long charging time. As the sec
`ondary battery at that time, a nickel-hydrogen battery is
`mainly used, so that most of the nickel-hydrogen batteries
`require along charging time of about 8 hours. In recent years,
`as a novel secondary battery, a high capacity and high density
`batteries such as lithium-ion secondary battery or the like
`have come into existence. As a result, with respect to the
`electronic equipments such as mobile phone, personal com
`puter or the like that are driven by a high power consumption
`and require a rapid charging operation, the non-contact type
`charging system has been eagerly reviewed in these days.
`As one example of the non-contact type charging appara
`tus, there have been proposed systems in Japanese Unexam
`ined Patent Application Publication No. 11-265814 (Patent
`Document 1) or Japanese Unexamined Patent Application
`Publication No. 2000-23393 (Patent Document 2). Both sys
`tems adopt a structure in which a ferrite core is used as a
`magnetic core and a coil is wound around the magnetic core
`thereby to realize the apparatus which is reduced in size.
`Further, in the charging apparatus disclosed in Japanese
`Unexamined Patent Application Publication No. 9-190938
`(Patent Document 3), ferrite powder and amorphous powder
`are mixed thereby to form a resin substrate and a coil or the
`like is mounted on the resin substrate thereby to realize the
`charging apparatus reduced in size and thickness.
`However, when ferrite is worked to be thin shape, the thin
`ferrite becomes brittle and has a low impact resistance, so that
`there has been posed a problem such that the power receiving
`system turns out to be defective due to a dropping or collision
`or the like of the apparatus. Further, in order to reduce a size
`in thickness of a power receiving portion so as to correspond
`to the reduction in thickness of the electronic equipment,
`there has been adopted a planar coil which is formed by
`printing a metal powder paste onto a coil. As one example of
`structure for strengthening bondage by using the planar coil
`and a magnetic sheet, there have been proposed the structures
`disclosed in Japanese Unexamined Utility Model Application
`Publication No. 58-80753 (Patent Document 4), Japanese
`Unexamined Patent Application Publication No. 4-122007
`(Patent Document 5) or Japanese Unexamined Patent Appli
`cation Publication No. 8-1483.60 (Patent Document 6). In
`these proposed structures, a magnetic body (magnetic sheet)
`is used as a core material for strengthening the bondage
`between a primary coil and a secondary coil.
`On the other hand, when an electric transmission rate is
`increased to be large, defects due to heat generation are liable
`to occur at portions not only the bondage between adjacent
`transformers but also peripheral parts of the transformers.
`That is, in a case where the planarcoil is used, a magnetic flux
`passing through the planarcoil is interlinked to a substrate or
`the like provided inside the equipment, so that a temperature
`of an inside of the apparatus is increased to generate heat due
`to eddy current caused by electromagnetic induction. As a
`result, there has been posed a problem such that high electric
`power cannot be transmitted and it takes long time to charge
`the electricity.
`To cope with this problem, the magnetic body (magnetic
`sheet) is used as also a shielding member with respect to a rear
`surface. In order to obtain a sufficient shielding effect, it has
`been considered that if the magnetic body (magnetic sheet)
`has the larger magnetic permeability or the wider area or the
`larger thickness, the more effective shielding effect can be
`obtained.
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`US 8,922,160 B2
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`Further, in order to increase the electric transmission rate,
`it is required to increase the electric power. However, when
`the electric transmission is continued to a metallic body, the
`metallic body generates heat due to the eddy current caused in
`the metallic body. Therefore, it is necessary to provide the
`following safety system. For example, in a case where a coil
`of a power transmitting (power Supplying) apparatus is a
`primary coil while a coil of a power receiving apparatus is a
`secondary coil and the primary coil is used as an antenna of
`RF-ID tag (radio-frequency-identification tag), the safety
`system judges whether or not the secondary coil exists at
`upper portion of the primary coil on the basis of a RF signal.
`However, in this case, when inductance of the primary coil
`is greatly changed in accordance with a positional relation
`ship between the magnetic body (magnetic sheet) and the coil
`of the power transmitting apparatus side, a resonant fre
`quency of a resonant circuit provided to a side of the primary
`coil for power transmitting is also greatly varied, so that there
`has been caused defects such that a sufficient resonance can
`not be obtained and the above antenna cannot function well.
`Patent Document 1: Japanese Unexamined Patent Applica
`tion Publication No. 11-265814
`Patent Document 2: Japanese Unexamined Patent Applica
`tion Publication No. 2000-23393
`Patent Document 3: Japanese Unexamined Patent Applica
`tion Publication No. 9-190938
`Patent Document 4: Japanese Unexamined Utility Model
`Application Publication No. 58-80753
`Patent Document 5: Japanese Unexamined Patent Applica
`tion Publication No. 4-122007
`Patent Document 6: Japanese Unexamined Patent Applica
`tion Publication No. 8-148360
`
`DISCLOSURE OF INVENTION
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`contact type power receiving apparatus further comprises a
`composite magnetic body which is provided to at least one
`portion between the secondary battery and the spiral coil, and
`a portion between the electronic device and the spiral coil,
`wherein the composite magnetic body comprises at least two
`layers including first and other layers of magnetic sheets
`(magnetic ribbons) through an insulating layer in which when
`a relative magnetic permeability of the first magnetic sheet
`provided to a side of the spiral coil is denoted as ud, a thick
`ness of the first magnetic sheet is denoted as tu, an average
`relative magnetic permeability of the other layers of magnetic
`sheets other than the first magnetic sheet is denoted as Lu, and
`a total thickness of the other layers of magnetic sheets is
`denoted as tu, the composite magnetic body satisfy the fol
`lowing relations: ud-tas60mm; and Lutua 100 mm.
`In the above non-contact type power receiving apparatus, it
`is preferable that the composite magnetic body satisfy the
`following relation: (Lutu)/(ud-ta)-10.
`Further, it is also preferable that the first magnetic sheet has
`a surface area larger than that of the other layers of the
`magnetic sheets, it is more preferable that the insulating layer
`of the composite magnetic body is composed of resin con
`taining magnetic powder, and it is also preferable that a dis
`tance between the first magnetic sheet and the other magnetic
`sheets is 30 Lum or more. Furthermore, it is also preferable that
`a total thickness of the composite magnetic body is 0.3 mm or
`less, and the secondary battery is a Li-ion secondary battery.
`The non-contact type power receiving apparatus according
`to the present invention is suitably applied to various elec
`tronic equipments. Further, when the electronic equipment of
`this invention is provided to a non-contact type power charg
`ing apparatus, there can be also provided a charging system
`capable of charging electricity to the electronic equipment.
`
`EFFECTS OF THE INVENTION
`
`According to the present invention, the composite mag
`netic body comprising a plurality of magnetic sheets (mag
`netic ribbons) is provided to at least one portion between the
`spiral coil (power receiving side spiral coil: a secondary coil)
`and the secondary battery, and a portion between the rectifier
`and the spiral coil. Therefore, magnetic flux generated from a
`power charging side spiral coil (a primary coil) is prevented
`from interlinking with a circuit board and the secondary bat
`tery or the like, and inductance variation in the preliminary
`coil, which is caused by absence or presence of the secondary
`coil, is controlled while noise and heat generation originated
`by induced electromotive force (electromagnetic induction)
`are Suppressed, so that a resonating property of a resonance
`circuit constituted by the primary coil is improved whereby
`an oscillation can be effectively controlled.
`
`BRIEF DESCRIPTION OF THE DRAWINGS
`
`FIG. 1 is an exploded perspective view showing an
`embodiment of the power receiving apparatus according to
`the present invention.
`FIG. 2 is an exploded perspective view showing another
`embodiment of the power receiving apparatus according to
`the present invention.
`FIG. 3 is a cross sectional view showing one embodiment
`of a composite magnetic body comprised by the power
`receiving apparatus according to the present invention.
`FIG. 4 is a cross sectional view showing one embodiment
`of a power charging system according to the present inven
`tion.
`
`As described above, in the power receiving apparatus for
`the conventional non-contact type charging system, the mag
`netic body (magnetic sheet) having a high permeability and a
`large Volume is provided to a Surface of the secondary coil, the
`Surface being opposite to a side of the primary coil, for the
`purpose of strengthening the bondage to improve an effi
`ciency of the electric power transmission and for the purpose
`of improving the shielding property thereby to suppress the
`heat generation. According to the above conventional
`arrangement, there has been posed problems such that a fluc
`tuation in inductance of the primary coil becomes notable,
`and an operating condition of the resonance circuit is disad
`Vantageously deviated from resonance condition capable of
`exhibiting a sufficient effect in accordance with the positional
`relationship between the magnetic body and the primary coil.
`The present invention had been achieved to solve the afore
`mentioned problems, and an object of the present invention is
`to provide a power receiving apparatus capable of improving
`the resonating property (resonation property) and capable of
`Suppressing the heat generation. Therefore, according to the
`electronic equipment and the power receiving system using
`the power receiving apparatus of the present invention, it
`becomes possible to increase the transmitting electricity, and
`it becomes also possible to shorten the charging time.
`To achieve the above object, the present invention provides
`a non-contact type power receiving apparatus comprising a
`power receiving coil having a spiral coil; a rectifier for recti
`fying alternative Voltage (AC Voltage) generated at the power
`receiving coil; a secondary battery for being charged with
`direct voltage (DC voltage) which is rectified by the rectifier;
`and an electronic device operated by being Supplied with the
`direct voltage from the secondary battery, wherein the non
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`BEST MODE FOR CARRYING OUT THE
`INVENTION
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`US 8,922,160 B2
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`composite magnetic body comprises: a first magnetic sheet, a
`second magnetic sheet and a third magnetic sheet from the
`side of the spiral coil.
`In the present invention, when a relative magnetic perme
`ability of the first magnetic sheet constituting the composite
`magnetic body is denoted as ud, a thickness of the first mag
`netic sheet is denoted as td (mm), an average relative mag
`netic permeability of the other layers of magnetic sheets other
`than the first magnetic sheet is denoted as Lu, and a total
`thickness of the other layers of magnetic sheets is denoted as
`tu (mm), the composite magnetic body satisfy the following
`relations: ud-tas60; and Lutus 100. The average relative
`magnetic permeability of the other layers of (after second)
`magnetic sheets other than the first magnetic sheet is obtained
`by measuring the respective relative magnetic permeabilities
`of each of the magnetic sheets, and followed by averaging the
`respective relative magnetic permeabilities. Further, the total
`thickness is obtained by measuring the respective thicknesses
`of each of the magnetic sheets, and followed by totalizing the
`respective thicknesses. A value (relative magnetic permeabil
`ity of the magnetic sheetxthickness of the magnetic sheet)
`indicates a magnetic resistance in a magnetic circuit.
`In the present invention, the structure is specified so that the
`composite magnetic body satisfies the following relations:
`ud-tas60; and Lutus 100. Since the first magnetic sheet is
`provided to a closest portion to the spiral coil, the first mag
`netic sheet is liable to affect resonating frequency at the time
`of charging operation. Therefore, when the relation: ud-tas60
`is established, the magnetic resistance can be increased and
`the magnetic flux can be prevented from being concentrated
`to the first magnetic sheet, so that it becomes possible to
`suppress a lossarisen in the first magnetic sheet and to prevent
`the resonating property from lowering.
`Further, when the relation: Lutual 00 is established, the
`magnetic resistance can be decreased and a shielding effect is
`improved, so that an eddy current generated at the Substrate or
`the like provided in the devices is suppressed thereby to
`reduce a heat generation. Namely, when only the first mag
`netic sheet is provided, the shielding effect is insufficient and
`the heat generation cannot be Suppressed. While, when only
`the other (after second) magnetic sheets are provided, the
`resonating property is lowered. For example, when only the
`magnetic sheets each satisfying the relation: Lutua 100 are
`formed into a multi-layered structure, the shielding property
`is improved, but the resonating property is disadvantageously
`lowered. To solve the above problem, the present invention
`adopts a structure in which the first magnetic sheet satisfying
`the relation: ud-tas60 is provided to the side of the spiral coil.
`Further, it is preferable that the structure satisfies a relation:
`(uu-tu)/(ud-ta)-10. As described above, the first magnetic
`sheet has a main function of improving the resonating prop
`erty, while the other (after second) magnetic sheets have a
`main function of improving the shielding property. When
`satisfying the relation: (Lutu)/(LLdtd) 10, functional contri
`butions of the first and the other magnetic sheets become
`clear, thereby to improve the characteristics of the power
`receiving apparatus.
`In this regard, an upper limit of the ratio of (Lutu)/(LLdtd)
`is not particularly limited, but the upper limit is preferably set
`to 70 or less. Even if the ratio of (uu-tu)/(ud-ta) exceeds 70, the
`same effect can be obtained. However, it is necessary to
`extremely enlarge Lu or tu, or make ud or td extremely small,
`so that it becomes difficult to manage a manufacturing con
`trol.
`Further, it is more preferable that the first magnetic sheet
`has a surface area larger than that of the other layers of the
`magnetic sheets constituting the composite magnetic body. In
`
`FIG. 1 is an exploded perspective view showing one
`embodiment of the power receiving apparatus according to
`the present invention. FIG. 2 is an exploded perspective view
`showing another embodiment of the power receiving appara
`tus according to the present invention. In the drawings, a
`reference numeral 1 denotes an electronic apparatus, a refer
`ence numeral 2 denotes a power receiving apparatus, a refer
`ence numeral 3 denotes an electronic apparatus body, a ref
`erence numeral 4 denotes a casing, a reference numeral 11
`denotes a spiral coil, a reference numeral 12 denotes a recti
`fier, a reference numeral 13 denotes a secondary battery, a
`reference numeral 14 denotes an electronic device provided
`to the electronic apparatus body, a reference numeral 15
`denotes a circuit board for mounting the electronic device,
`and a reference numeral 16 denotes a composite magnetic
`body.
`Further, FIG. 1 shows an embodiment where the composite
`magnetic body 16 is provided to a portion between the spiral
`coil 11 and the secondary battery 13, while FIG. 2 shows an
`embodiment where the composite magnetic body 16 is pro
`vided to a portion between the electronic device 14 and the
`spiral coil 11.
`At first, the power receiving apparatus of the present inven
`tion comprises: the spiral coil; the rectifier, the secondary
`battery; and the electronic device. The spiral coil is not par
`ticularly limited, but may be formed by winding metal wire
`Such as copper or the like, or formed by a planar coil which is
`formed by printing metal powder paste, followed by drying
`the printed paste. Further, a winding shape of the spiral coil is
`not particularly limited, but may be formed into circular,
`elliptical-shape, or rectangular-shape, polygonal-shape. A
`winding number of the spiral coil may be controlled in accor
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`dance with the required characteristics.
`Further, the rectifier is formed of various semiconductor
`elements such as transistor, diode and so on. Furthermore, the
`number of the rectifier is arbitrarily specified, so that one or at
`least two rectifiers are provided so as to meet requirements. In
`this regard, although the rectifier 12 is provided to an antenna
`side of the circuitboard 15 as shown in FIG.1, the rectifier 12
`may also be provided to a surface opposed to the antenna.
`Further, the rectifier may also be formed by a film-forming
`technology such as TFT or the like.
`The secondary battery 13 is capable of charging/discharg
`ing electricity, and there can be used secondary batteries
`having various shapes such as plain-shape, button-shape. The
`electronic device 14 denotes various elements such as resis
`tance element, capacitative element, inductance element,
`controlling element or the like for constituting a circuit. Fur
`ther, the circuit board 15 is an insulating board composed of
`resin film or ceramic substrate or the like onto which the
`electronic devices are mounted thereby to form the circuit.
`The composite magnetic body 16 comprises at least two
`layers of magnetic sheets (magnetic ribbons) through an insu
`lating layer. In the magnetic sheets of at least two layers, a
`magnetic sheet provided to a side of the spiral coil is referred
`as a first magnetic sheet, while magnetic sheets other than the
`first magnetic sheet are referred as Subsequent (after second,
`or the other) magnetic sheets. The magnetic sheets after sec
`ond are called as a second magnetic sheet, a third magnetic
`sheet, —and so on in turn from a side of the first magnetic
`sheet. Therefore, in case of two layers of the magnetic sheets,
`the composite magnetic body comprises: a first magnetic
`sheet and a second magnetic sheet from the side of the spiral
`coil. While, in case of three layers of the magnetic sheets, the
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`a case where a plurality of the other (after second) magnetic
`sheets are provided, the Surface area of the other magnetic
`sheets is defined as a largest Surface area among the respective
`other magnetic sheets. When the surface area of the first
`magnetic sheet is larger than that of the other layers of the
`magnetic sheets, it becomes possible to prevent the resonat
`ing property from lowering.
`Further, the insulating layer constituting the composite
`magnetic body is not particularly limited, but the insulating
`layer may be formed as an inorganic insulating layer, an
`organic insulating layer or the like. The insulating layer is
`preferably formed as the organic insulating layer using insu
`lating resin. The insulating resin can be used in various forms
`Such as an adhesive agent, a film, rubber or the like. Such
`insulating resin may be provided in accordance with a size of
`the magnetic sheet.
`Further, the insulating layer can be also formed by com
`bining the insulating film, adhesive agent, rubber or the like.
`One example is an insulating film with an adhesive agent.
`Furthermore, as examples of the insulating resin, for
`example, natural rubber, neoprene rubber, chloroprene rub
`ber, silicone rubber, Hypalon; other synthetic rubber, PVC
`resin, ethylene-Vinyl acetate copolymer resin, acrylic resin,
`silicone resin, polyurethane resin, polypropylene resin, poly
`ester resin, polyimide resin, polycarbonate resin, polyethyl
`ene terephthalate resin, polyethylene naphthalate resin, poly
`buthylene naphthalate resin, polyester elastomer resin,
`fluorine resin, other synthetic resins can be used. In a case
`where the insulating layer is not provided and the first and the
`other magnetic sheets are directly contacted to face-to-face,
`an effect of sharing roles (functions) cannot be sufficiently
`obtained. Namely, when the first and the other magnetic
`sheets are directly Surface-contacted to each other, the con
`tacted magnetic sheets function as one magnetic sheet.
`Further, the insulating layer is sufficient as far as the insu
`lating property for the respective magnetic sheets is main
`tained. As to an outermost layer of the magnetic sheet,
`whether the insulating layer is provided or not will make no
`problem. However, when the insulating layer is provided to
`the outermost layer of the magnetic sheet, an insulating prop
`erty against peripheral members (circuit board, secondary
`battery, spiral coil) can be maintained, thus being preferable.
`One example of the insulating layer is shown in FIG. 1.
`FIG. 3A shows one Example in which an adhesive layer
`and an insulating film as the insulating layers are provided to
`one surface of the magnetic sheet, while FIG. 3B shows
`another Example in which the adhesive layer and the insulat
`ing film as the insulating layers are provided to both Surfaces
`of the magnetic sheet. In figures, a reference numeral 5
`denotes the insulating film, a reference numeral 6 denotes the
`50
`adhesive layer, and a reference numeral 7 denotes the mag
`netic sheet. When this magnetic sheet and the insulating layer
`are laminated and the resultant laminated body is multi-lay
`ered, thereby to form a composite magnetic body for use in an
`embodiment of the present invention.
`Further, it is preferable that the insulating layer of the
`composite magnetic body is composed of resin containing
`magnetic powder. When the magnetic powder is contained in
`the insulating layer, the shielding effect can be improved and
`the heat generation can be sufficiently prevented. Examples
`60
`of the magnetic powder include: ferrite powder, Sendust pow
`der, amorphous powder or the like.
`Further, in the above composite magnetic body, it is pref
`erable that a distance between the first magnetic sheet and the
`other magnetic sheets is 30 um or more. The distance between
`the first magnetic sheet and the other magnetic sheets is
`defined as a thickness of an insulating layer for insulating the
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`30
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`35
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`40
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`45
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`55
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`65
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`US 8,922,160 B2
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`5
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`10
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`15
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`25
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`8
`first and second magnetic sheets. Therefore, the preferable
`thickness of the insulating layer is 30 um or more.
`As described hereinbefore, when the first and the other
`magnetic sheets are directly surface-contacted to each other,
`the contacted magnetic sheets function as one magnetic sheet.
`Therefore, it is necessary to prevent the surface-contact of the
`first and second magnetic sheets by interposing the insulating
`layer therebetween. On the other hand, when the thickness of
`the insulating layer is excessively thin, there may be a fear that
`the insulating effect between the two magnetic sheets
`becomes insufficient. Therefore, it is preferable to set the
`thickness of the insulating layer to 30 um or more.
`In this connection, an upper limit of the thickness of the
`insulating layer (i.e., a distance between the first magnetic
`sheet and the other magnetic sheets) is preferably set to 200
`um or less. When the thickness of the insulating layer is
`excessively thick, the distance between the first magnetic
`sheet and the other magnetic sheets is excessively apart, so
`that the effect of sharing rolls cannot be sufficiently obtained.
`In addition, a total thickness of the composite magnetic body
`becomes excessively large, so that it becomes difficult to
`make the composite magnetic body to be compact in size. In
`this regard, the total thickness of the composite magnetic
`body is preferably set to 0.3 mm or less.
`Further, the magnetic sheet constituting the composite
`magnetic sheet is not particularly limited as far as the mag
`netic sheet satisfies the aforementioned relative permeabil
`ityxthickness. However, the magnetic sheet may be prefer
`ably formed of magnetic materials such as Co-type
`amorphous all