llIIlIlllIlIlIllIlIllIllIllIIlllIIllIlIlllIIllIllIIllIlllIlIIIlllllIlIIlllIIIIIIIIIIIIIIII
`US 20090284341A1
`
`119) United States
`112) Patent Application Publication
`Okada et al.
`
`110) Pub. No. : US 2009/0284341 A1
`Nov. 19, 2009
`(43) Pub. Date:
`
`154) COIL UNIT AND ELECTRONIC APPARATUS
`USING THE SAME
`
`175)
`
`Inventors:
`
`Hirofumi Okada, Suwa-shi 1JP);
`Yoichiro Kondo, Chino-shi 1JP)
`
`Correspondence Address:
`OLIFF 4 BERRIDGE, PLC
`P. O. BOX 320850
`ALEXANDRIA, VA 22320-4S50 (US)
`
`173) Assignee:
`
`SEIKO EPSON
`CORPORATION, Tokyo 1JP)
`
`121) Appl. No. :
`
`12/429, 7S1
`
`122) Filed:
`
`Apr. 24, 2009
`
`130)
`
`Foreign Application Priority Data
`
`1JP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2008-126747
`May 14, 2008
`Publication Classification
`
`151) Int. Cl.
`H01F 27/28
`152) U. S. Cl. .
`157)
`
`12006. 01)
`
`ABSTRACT
`
`336/232
`
`A coil unit includes a coil formed by winding a coil wire, a
`wiring substrate, and a magnetic substance for receiving mag-
`netic lines of force generated by the coil. The wiring substrate
`includes a connection terminal connected to both ends of the
`coil, an external connection terminal, and a wiring pattern for
`the connection terminal and the external connec-
`connecting
`the coil is
`terminal. No circuit element other
`tion
`than
`mounted on the wiring substrate.
`
`140e-.
`
`130
`
`I
`I
`
`P
`io". '
`
`130a
`
`130b
`
`130c
`
`140h
`
`140e
`
`143
`
`142
`
`142a,
`141a
`
`141
`
`18'!
`
`183
`
`182
`
`150
`
`144
`
`Petitioner Samsung and Google Ex-1006, 0001
`
`

`

`Patent Application Publication
`
`Nov. 19, 2009 Sheet 1 of 13
`
`US 2009/0284341 A1
`
`~ ooo oo
`
`OG
`
`10
`
`Petitioner Samsung and Google Ex-1006, 0002
`
`

`

`Patent Application Publication
`
`Nov. 19, 2009 Sheet 2 of 13
`
`US 2009/0284341 A1
`
`30c
`
`40h
`
`- 30
`
`50
`
`Petitioner Samsung and Google Ex-1006, 0003
`
`

`

`Patent Application Publication
`
`Nov. 19, 2009 Sheet 3 of 13
`
`US 2009/0284341 A1
`
`60
`
`70
`
`503
`
`308
`
`I
`I
`I
`I
`I I (I
`
`/I
`
`7
`
`I
`I
`I
`I
`g
`
`40b
`
`40h
`
`41
`
`42m
`
`Petitioner Samsung and Google Ex-1006, 0004
`
`

`

`Patent Application Publication
`
`Nov. 19, 2009 Sheet 4 of 13
`
`US 2009/0284341 A1
`
`Petitioner Samsung and Google Ex-1006, 0005
`
`

`

`Patent Application Publication
`
`Nov. 19, 2009 Sheet 5 of 13
`
`US 2009/0284341 A1
`
`FIG. 7
`
`0
`
`o
`
`41
`
`401
`
`1/0
`
`100 ~
`
`l12
`
`Petitioner Samsung and Google Ex-1006, 0006
`
`

`

`Patent Application Publication
`
`Nov. 19, 2009 Sheet 6 of 13
`
`US 2009/0284341 A1
`
`FREQUENCY-EQUIVALENT RESISTANCE CI-IARACTERISTIC
`
`0, 5
`
`0. 5 5
`
`0. 5
`
`0 45
`
`u~ 04
`
`~~ 0. 35
`
`0, 3
`
`0. 2
`50000
`
`90000
`
`110000
`
`130DDO
`
`150000
`
`FREQUENCYI:Hz)
`
`~ COIL UNIT('1) ~ COIL UNIT(2) ~ COIL UNIT(3) ~ COIL UNIT(4) ~ COIL UNIT(5) ~ COIL UNIT(6)
`
`Petitioner Samsung and Google Ex-1006, 0007
`
`

`

`Patent Application Publication
`
`Nov. 19, 2009 Sheet 7 of 13
`
`US 2009/0284341 A1
`
`1. 18E-05
`1, 16E-05
`
`1, 14E-05
`X 1, 12E-05
`~ ~1, 10E-05
`o 1. 08E-05
`C3 1. 06E-05
`1, 04E-05
`
`1. 0ZE-05
`
`1. 00E-05
`50000
`
`FREQUENCY-INDUCTANCE
`
`90000
`
`li0000
`
`l30000
`
`150000
`
`FREQUENCYIHz]
`
`~ COIL UNIT(1) ~ COIL UNIT(2) ~ COIL UNIT(3) ~ COIL UNIT(4) ~ COIL UNIT(5) ~ COIL UNIT(6)
`
`Petitioner Samsung and Google Ex-1006, 0008
`
`

`

`Patent Application Publication
`
`Nov. 19, 2009 Sheet 8 of 13
`
`US 2009/0284341 A1
`
`UNIT No.
`
`MAGNETIC
`SHE ET61
`
`MAGNETIC
`SHE ET62
`
`INDUCTANCE
`(p H)
`
`RESIST-I. g ]
`
`ANCE
`
`11, 392
`
`11. 345
`
`0. 318
`
`20, 0'I 728
`
`21. 83864
`
`0. 382
`
`18. 73771
`
`18. 80811
`
`20. 45790
`
`18, 37030
`
`(6)
`
`Petitioner Samsung and Google Ex-1006, 0009
`
`

`

`Patent Application Publication
`
`Nov. 19, 2009 Sheet 9 of 13
`
`US 2009/0284341 A1
`
`rrr
`rr
`
`140e-.
`
`I
`l
`I
`I
`
`~ r
`I~:
`I
`I
`
`t
`142m
`
`141
`
`)
`141
`
`180
`
`18'!
`
`182
`
`150
`
`140e
`
`143
`
`Petitioner Samsung and Google Ex-1006, 0010
`
`

`

`Patent Application Publication
`
`Nov. 19, 2009 Sheet 10 of 13
`
`US 2009/0284341 A1
`
`181
`
`192
`
`Petitioner Samsung and Google Ex-1006, 0011
`
`

`

`Patent Application Publication
`
`Nov. 19, 2009 Sheet 11 of 13
`
`US 2009/0284341 A1
`
`OI
`CL ~
`LLI 0
`
`EL EL
`
`UJ O
`OO
`CL
`
`~O ~ EL I—
`OO O
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`Qgl-
`O~~ — la 0
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`ELO
`UJ I — I—
`«ELK O~~
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`LU
`
`O
`yV3I—
`O fD ~
`
`EL
`
`O~
`EE' CG O
`
`O
`~ ~ ELI-
`CO I—
`Z:
`-O~
`
`~ ~ ~I—
`Ow
`
`EO ~
`co I—
`
`I EL
`EL ~
`O
`
`Petitioner Samsung and Google Ex-1006, 0012
`
`

`

`Patent Application Publication
`
`Nov. 19, 2009 Sheet 12 of 13
`
`US 2009/0284341 A1
`
`Petitioner Samsung and Google Ex-1006, 0013
`
`

`

`Patent Application Publication
`
`Nov. 19, 2009 Sheet 13 of 13
`
`US 2009/0284341 A1
`
`& OOO
`
`OO
`OO
`
`42
`
`k
`
`/
`
`/
`
`21
`
`25
`
`24
`
`Petitioner Samsung and Google Ex-1006, 0014
`
`

`

`US 2009/0284341 A1
`
`Nov. 19, 2009
`
`COIL UNIT AND ELECTRONIC APPARATUS
`USING THE SAME
`
`BACKGROUND
`
`[0001] 1. Technical Field
`[0002] Several aspects of the present invention relates to a
`coil unit suitable for contactless power transmission
`and an
`electronic apparatus or the like using the coil unit.
`[0003] 2. Related Art
`[0004] There is known contactless power transmission
`that
`to transmit power without
`uses electromagnetic
`induction
`using a metal contact. As applications of contactless power
`charging of a cell phone, charging of a home
`transmission,
`appliance (e. g. , a handset), and the like have been proposed.
`[0005]
`In recent years, cell phones are required to be down-
`sized further. For this reason, a coil unit for transmitting
`power must also be further downsized, particularly,
`in the
`thickness dimension. For the purpose of providing a battery
`pack interface whose use allows charging a cell phone includ-
`ing a battery pack by only placing the cell phone on a power
`transmission apparatus, JP-A-2006-311712 discloses a tech-
`nology for transmitting power to a cell phone (I) including a
`battery pack (3) storing a protection circuit (5) and a second-
`ary battery (4) and a charging control circuit (6) via contact
`terminals (9) and (10) using a battery pack lid (2) including a
`interface (8) and a rectifier circuit (7).
`power transmission
`In JP-A-2006-311712, a coil serving as the power
`[0006]
`interface (8) is included
`in the battery pack lid
`transmission
`(2) together with the rectifier circuit (7). The inclusion of the
`rectifier circuit (7) makes
`the battery pack lid (2) thicker.
`Also, the battery pack lid (2) is available only as a battery
`pack; therefore,
`its use condition,
`in
`that is, its flexibility
`restricted.
`usage is significantly
`
`SUMMARY
`[0007] An advantage of an aspect of the invention
`is to
`provide a coil unit that has greater flexibility
`in its insertion
`insertion space, and inser-
`position in an electronic apparatus,
`tion method, and an electronic apparatus using the coil unit.
`[0008] A coil unit according to an aspect of the invention
`includes a coil formed by winding a coil wire, a wiring sub-
`strate, and a magnetic substance for receiving magnetic
`lines
`of force generated by the coil. The wiring substrate
`includes
`terminal connected to both ends of the coil, an
`a connection
`terminal, and a wiring pattern for con-
`external connection
`terminal and the external connection
`necting the connection
`terminal. No circuit element other than the coil is mounted on
`the wiring substrate.
`[0009] The coil unit according to the aspect of the invention
`is separated from a coil control unit. This coil unit is coupled
`to the coil control unit via the external connection terminal.
`elements of the coil unit are the coil,
`Since the minimum
`the coil unit is
`substance,
`substrate, and magnetic
`wiring
`downsized or slimmed down. Thus, the coil unit has greater
`in its insertion position in an electronic apparatus,
`flexibility
`space, and insertion method. Depending on the
`insertion
`materials of the coil and magnetic substance,
`it is difficult to
`the shape of the coil unit with only the coil and
`maintain
`substance; however,
`integration with the wiring
`magnetic
`substrate, which is a rigid body, allows the coil unit to main-
`tain its shape.
`In the aspect of the invention,
`[0010]
`the coil may be a flat
`coil. A flat coil may be formed by winding a coil wire around
`
`the magnetic substance using the magnetic substance as the
`core or may be an air-core coil formed by winding a coil wire
`on a plane in a spiral fashion. Use of a flat coil further ensures
`slimming down of the coil unit.
`[0011] In the aspect of the invention,
`the wiring substrate
`may have a coil housing, and the coil may be housed in the
`coil housing. Thus, a part or all of the thickness of the coil is
`absorbed by the thickness of the substrate. This further
`ensures slimming down of the coil unit.
`In the aspect of the invention,
`[0012]
`the coil may be an
`air-core coil formed by winding
`the coil wire on a plane, and
`the inner terminal of the coil wire may be drawn from the
`surface of the coil.
`non-transmission
`[0013] This prevents
`the coil inner end drawing
`line from
`surface. This makes
`forming protrusions on the transmission
`the distance
`surface flat, thereby reducing
`the transmission
`surface of the primary coil and that
`between the transmission
`of the secondary coil. As a result, the transmission efficiency
`is improved.
`In the aspect of the invention,
`[0014]
`the coil unit may
`further include a spacer disposed between the non-transmis-
`sion surface of the coil and the magnetic substance. Thus,
`even if the magnetic substance
`is not flexible, recesses and
`surface of the
`formed on the non-transmission
`protrusions
`coil by the coil inner end drawing
`line are absorbed by the
`spacer.
`In the aspect of the invention,
`[0015]
`sub-
`the magnetic
`stance may be a multilayer body where a plurality of magnetic
`substances are layered. The respective magnetic substances
`may be an identical type of magnetic substances or different
`types of magnetic substances. If the magnetic substance
`is a
`multilayer body where a plurality of magnetic substances are
`layered, coil characteristics
`(inductance, resistance, Q value,
`or the like) that cannot be obtained with a single magnetic
`lines of force-
`substance are obtained. Also, since magnetic
`lines of force are confined within a magnetic path
`magnetic
`formed by the two magnetic substances,
`leakage magnetic
`flux is reduced. Therefore, a shield plate does not always need
`to be provided. This slims down the coil unit.
`[0016] The coil magnetic substance may include first and
`second magnetic substances having different characteristics,
`particularly, different magnetic permeabilities. Combination
`of two magnetic substances having different characteristics
`allows obtaining coil characteristics
`(inductance, resistance,
`Q value, or the like) that cannot be obtained with a single
`magnetic substance or a multilayer body where an identical
`type of magnetic substances are layered. Also, since magnetic
`lines of force are confined within a
`lines of forcemagnetic
`leak-
`magnetic path formed by the two magnetic substances,
`age magnetic flux is reduced. Therefore, a shield plate does
`not always need to be provided. This slims down the coil unit.
`In the aspect of the invention,
`resis-
`[0017]
`the equivalent
`tance of the coil at the time when the first magnetic substance
`is used as the magnetic path may be smaller than the equiva-
`lent resistance of the coil at the time when the second mag-
`is used as the magnetic path, and the induc-
`netic substance
`tance of the coil at the time when the first magnetic substance
`is used as the magnetic path may be smaller than the induc-
`tance of the coil at the time when the second magnetic sub-
`stance is used as the magnetic path. This allows obtaining a
`coil having a characteristic range that cannot be obtained with
`a coil unit where only one of the two magnetic substances
`is
`used in a single layer or multiple
`layers.
`
`Petitioner Samsung and Google Ex-1006, 0015
`
`

`

`US 2009/0284341 A1
`
`Nov. 19, 2009
`
`[001S] In the aspect of the invention,
`the first magnetic
`the coil wire and the
`substance may be disposed between
`second magnetic substance. By disposing
`the first magnetic
`substance, which can reduce the equivalent
`resistance, near
`the coil wire, the transmission efficiency is improved.
`[0019] In the aspect of the invention,
`the coil unit may
`further include a temperature detection element and a flexible
`detection element
`substrate on which
`is
`the temperature
`mounted. The flexible substrate may be interposed between
`the coil wire and the magnetic substance.
`[0020] Thus, the coil unit is slimmed down while the tem-
`is disposed in any position adja-
`perature detection element
`cent to the coil. If an air-core coil is used as the coil, the
`temperature detection element may be disposed
`in the air-
`core of the coil. If a foreign object intrudes
`into the air-core
`having a high magnetic flux density of the air-core coil, heat-
`ing caused by an eddy current generated by the foreign object
`becomes extremely significant. The temperature of the for-
`eign object or that of the coil is detected using the temperature
`detection element, such as a thermistor,
`that is mounted on the
`flexible substrate and disposed in the air-core of the air-core
`coil.
`[0021] An electronic apparatus according to another aspect
`of the invention
`includes an insertion part into which
`the
`coil unit is to be inserted and a main body
`above-mentioned
`to be connected to the external connection terminal
`terminal
`of the coil unit. Since the coil unit is downsized or slimmed
`down, it has greater flexibility
`in its insertion position in the
`insertion part of the electronic apparatus and in its insertion
`space. Also, the coil unit has greater flexibility in its insertion
`method such as slot-in or insertion into a lid such as a battery
`lid.
`
`BRIEF DESCRIPTION OF THE DRAWINGS
`
`showing a sec-
`
`[0022] The invention will be described with reference to the
`like reference numerals
`drawings, wherein
`accompanying
`like elements.
`represent
`[0023] FIG. 1 is a drawing schematically showing a charger
`and an electronic apparatus charged by the charger, such as a
`cell phone.
`[0024] FIG. 2 is a drawing showing an example of a con-
`tactless power transmission method.
`[0025] FIG. 3 is a drawing schematically
`ondary coil unit.
`[0026] FIG. 4 is an exploded perspective view schemati-
`the secondary coil unit.
`cally showing
`[0027] FIG. 5 is a drawing schematically showing a section
`taken along line V-V of FIG. 3.
`[002S] FIG. 6 is a sectional view of a coil wire.
`[0029] FIG. 7 is a drawing showing a form where a second-
`ary coil unit and a control unit are electrically connected.
`[0030] FIG. S is a graph showing
`frequency-equivalent
`resistance characteristics obtained from an experiment.
`[0031] FIG. 9 is a graph showing
`frequency-inductance
`characteristics obtained from the experiment.
`[0032] FIG. 10 is a table where values at a frequency of
`100, 000 Hz extracted
`from characteristics
`in the
`shown
`above-mentioned
`graphs are organized.
`[0033] FIG. 11 is an exploded perspective view schemati-
`the primary coil unit.
`cally showing
`[0034] FIG. 12 is a schematic perspective view of a power
`the primary coil unit and a
`transmission
`apparatus where
`control unit are electrically connected.
`
`[0035] FIG. 13 is a schematic block diagram of the primary
`and secondary coil units shown in FIG. 12 and control units
`connected thereto.
`[0036] FIG. 14 is a schematic perspective view showing a
`main part of a modification of a coil unit.
`[0037] FIG. 15 is a drawing showing a modification where
`the secondary coil unit can be attached to or detached from an
`electronic apparatus.
`
`DESCRIPTION OF EXEMPLARY
`EMBODIMENT
`[003S] Now, a preferred embodiment of the invention will
`be described in detail. The embodiment described below does
`limit the invention as set forth in the appended
`not unduly
`claims. Also, not all the configurations
`described
`in the
`the above-
`are essential as means for solving
`embodiment
`mentioned problems.
`[0039] 1. Charging System
`[0040] FIG. 1 is a drawing schematically showing a charger
`10, which is also an example of an electronic apparatus, and
`a cell phone 20, which is an example of an electronic appa-
`ratus changed by the charger 10. FIG. 1 shows the cell phone
`20 to be transversely placed on the charger 10. The cell phone
`20 is charged by the charger 10 by means of contactless power
`induction action gen-
`transmission using an electromagnetic
`erated between a coil of a coil unit 12 of the charger 10 and a
`coil of a coil unit 22 of the cell phone 20.
`[0041] The charger 10 and cell phone 20 may each have a
`positioning structure. For example, the charger 10 may have
`a positioning protrusion protruding out of the outer surface of
`the case thereof. On the other hand, the cell phone 20 may
`recess on the outer surface of the case
`have a positioning
`the coil unit 22
`thereof. By using such positioning structures,
`of the cell phone 20 is at least disposed in a position opposed
`to the coil unit 12 of the charger 10.
`shown in FIG. 2, power is trans-
`[0042] As schematically
`mitted from the charger 10 to the cell phone 20 by electro-
`magnetically coupling a primary coil L1 (power transmission
`in the charger 10 and a secondary coil L2
`coil) included
`in the cell phone 20 and thus
`(power reception coil) included
`transformer. This realizes con-
`forming a power transmission
`that FIG. 2 shows an
`tactless power
`transmission. Note
`example of electromagnetic
`coupling between
`the primary
`coil L1 and secondary coil L2 and that another type of elec-
`lines of forcemagnetic
`tromagnetic coupling where magnetic
`lines of force are formed in a way different from that in FIG.
`2 may be adopted.
`[0043] 2. Coil Unit of Cell Phone 20
`[0044] FIG. 3 is a drawing schematically
`the coil
`showing
`unit 22 (secondary coil unit) of the cell phone 20. FIG. 4 is an
`the coil
`exploded perspective view schematically
`showing
`unit 22 of the cell phone 20. In FIGS. 3 and 4, the non-
`surface of the coil unit 22 opposite to the trans-
`transmission
`to the coil unit 12 of the
`mission surface thereof opposed
`charger 10 in FIG. 1 is seen from above. The transmission
`surfaces refer to the respective surfaces of the coil unit 22 and
`the coil unit 12 opposed
`to each other in FIG. 1 and the
`surfaces refer to the respective
`non-transmission
`surfaces
`surfaces of the coil unit 12 and
`opposite to the transmission
`coil unit 22. FIG. 5 is a drawing
`showing a
`schematically
`section taken along line V-V of FIG. 3. FIG. 6 is a sectional
`view showing an example of a coil wire. FIG. 7 shows a form
`in which the coil unit 22 and a control unit (coil control unit)
`100 are electrically coupled.
`
`Petitioner Samsung and Google Ex-1006, 0016
`
`

`

`US 2009/0284341 A1
`
`Nov. 19, 2009
`
`3
`
`[0045] The coil unit 22 includes a coil 30, a wiring substrate
`40, and a magnetic substance 60 as minimum elements. In this
`embodiment, a coil housing 40a may be formed on the wiring
`surface of the coil 30 is
`substrate 40 so that the transmission
`positioned on the back surface of the wiring substrate 40. For
`the coil housing 40a is a hole that penetrates
`the
`example,
`wiring substrate 40 in the thickness direction. Also, in this
`a protection sheet 50 for protecting
`the trans-
`embodiment,
`mission surface of the coil 30 may be provided on the back
`surface of the wiring substrate 40 shown in FIG. 4.
`[0046] The wiring substrate 40 is provided with connection
`terminals 40b to which both the ends of the coil 30 are con-
`nected, external connection terminals 41 and 42, and wiring
`patterns 41 a and 42a. No circuit element other than the coil 30
`is mounted on the wiring substrate 40. The external connec-
`tion terminals 41 and 42 are terminals used when connecting
`the coil unit 22 to an external apparatus
`such as the control
`unit 100 shown in FIG. 7. The wiring patterns 41a and 42a
`terminals 40b and external
`connect between the connection
`terminals 41 and 42. While the wiring patterns
`connection
`41a and 42a may be formed on the front surface (the surface
`on which the terminals 40b, 41a, and 42a are formed) of the
`wiring substrate 40 shown in FIG. 4, these patterns may be
`provided on the back surface of the wiring substrate 40 and
`to the terminals 40b, 41a, and 42a via through-
`connected
`holes.
`In this embodiment, as shown in FIG. 7, the second-
`[0047]
`ary coil unit 22 is separated from the secondary control unit
`100. The secondary coil unit 22 is coupled to the secondary
`control unit 100 via the external connection terminals 41 and
`42. Since the minimum elements of the coil unit 22 are the coil
`30, wiring substrate 40, and magnetic substance 60, the coil
`unit 22 is downsized or slimmed down. Thus, the coil unit 22
`has greater flexibility in its insertion position in the electronic
`apparatus 20, insertion space, and insertion method. Depend-
`ing on the materials of the coil 30 and magnetic sheet 60, the
`coil unit 22 is difficult to maintain
`its shape with only the coil
`30 and magnetic sheet 60; however,
`integration with the wir-
`ing substrate 40, which is a rigid body, allows the coil unit 22
`to maintain
`its shape.
`in FIG. 7 includes a
`[004S] The control unit 100 shown
`substrate 110 on which various electronic components
`for
`the secondary coil 130 are mounted. The
`drive-controlling
`substrate 110 is provided with external connection terminals
`111 and 112 electrically connected to the external connection
`terminals 41 and 42 formed on the substrate 40 of the sec-
`ondary coil unit 22. The control unit 100 will be described
`later.
`[0049] The coil 30 is, for example, a flat coil. The magnetic
`substance 60 takes the shape of a sheet or a plate. Hereafter, a
`sheet-shaped magnetic substance will be also referred to as a
`magnetic sheet. The magnetic sheet 60 is provided
`in such a
`surface of
`that it is opposed to the non-transmission
`manner
`the flat coil 30. In this embodiment,
`the magnetic sheet 60 is
`surface of the flat coil 30 and
`bonded to the non-transmission
`the wiring substrate 40 with a spacer 70 (e. g. , double-sided
`tape) therebetween.
`[0050] The flat coil 30 is not limited to any particular coil if
`it is a flat coil. For example, an air-core coil formed by
`coated coil
`winding a single-conductor or multi-conductor,
`wire on a plane may be used. In this embodiment,
`a coil
`coil wire 31, whose
`formed by winding a single-conductor
`section is a rectangle with a width W and a height H, on a
`plane as shown in FIG. 6 is used; however, the section is not
`
`the coil unit 22 according to this
`limited thereto. Hereafter,
`embodiment will be described taking the flat coil 30 having an
`air-core 30a (see FIGS. 4, 5) as an example.
`[0051] As described above, the flat coil 30 is housed in the
`coil housing 40a provided on the wiring substrate 40. This
`allows slimming down the coil unit 22 by a part or all of the
`thickness H (see FIG. 6) of the flat coil housed
`in the coil
`housing 40a. This also makes it easy to make the transmission
`surface of the flat coil 30 flush with the adjacent surface.
`in this embodiment, no recesses or protrusions are
`Actually,
`formed on the protection sheet 50. Also, the coil housing 40a
`the external shape of the flat coil
`has a shape corresponding
`30. Thus, if the flat coil 30 is only housed in the coil housing
`in the wiring substrate 40.
`40a, the flat coil 30 is positioned
`This facilitates positioning. As shown in FIG. 4, the wiring
`substrate 40 has multiple positioning holes 40e, and the pro-
`tection sheet 50 has multiple positioning holes 50a (only one
`is shown in FIG. 4).
`[0052] The coil unit 22 may be assembled,
`for example,
`using fixtures. First, the pins of the fixtures are passed through
`the positioning holes 50a of the protection sheet 50 and the
`positioning holes 40e of the wiring substrate 40, and then the
`protection sheet 50 having a single-sided
`tape and wiring
`substrate 40 are laminated. Next, the coil 30 is disposed in the
`coil housing 40a of the wiring substrate 40 and bonded to the
`protection sheet 50. Then, the magnetic sheet 60 is bonded to
`the wiring substrate 40 with the spacer 70 therebetween
`in
`that the spacer 70 covers the coil 30. Finally,
`such a manner
`both ends of the flat coil 30 are soldered to the connection
`terminals 40b of the wiring substrate 40. This completes the
`coil unit 22. While the protection sheet 50 is a sheet for
`protecting at least the flat coil 30, it covers both the transmis-
`sion surfaces of the wiring substrate 40 and coil 30 in this
`embodiment. The protection sheet 50 may have a hole in a
`to the air-core 30a.
`position corresponding
`[0053] The flat coil 30 has a coil inner end drawing line 30b
`the inner end of the coil and a coil outer end
`for drawing
`line 30c for drawing the outer end thereo f. As shown
`drawing
`in FIG. 4, the coil inner end drawing
`line 30b is preferably
`surface of the flat coil 30.
`drawn from the non-transmission
`line 30b from form-
`the coil inner end drawing
`This prevents
`ing protrusions on the transmission
`surface. This keeps the
`surface flat, as well as reduces
`the distance
`transmission
`surfaces of the primary
`between the respective transmission
`coil L1 and secondary coil L2 shown in FIG. 2. As a result, the
`transmission efficiency is increased.
`[0054] The wiring substrate 40 has a drawing
`line housing
`40h connecting with the coil housing 40a (see FIGS. 3 to 5).
`to house the coil
`The drawing
`line housing 40h is intended
`inner end drawing line 30b o f the flat coil 30 and coil outer end
`line 30c thereof. While only the coil outer end draw-
`drawing
`ing line 30c is shown in FIG. 5, the same goes for the coil
`line 30b. Since the drawing
`lines 30b and
`inner end drawing
`30c are housed in the drawing
`line housing 40h, that area is
`slimmed down by the thicknesses of the drawing
`lines 30b
`and 30c. Also, as shown in FIG. 4, the drawing
`lines 30b and
`line 30c is shown in FIG. 5) are bent
`30c (only the drawing
`relatively gently and then go up onto the wiring substrate 40.
`This reduces wire breaks.
`line 30b and coil outer
`[0055] The coil inner end drawing
`line 30c are drawn to the contact terminal 40b
`end drawing
`serving as connection terminals of the coil 30 and then elec-
`trically connected to the patterns on the wiring substrate 40 by
`soldering 40g as shown in FIGS. 3 and 5. The contact termi-
`
`Petitioner Samsung and Google Ex-1006, 0017
`
`

`

`US 2009/0284341 A1
`
`Nov. 19, 2009
`
`nals 40b are provided on the non-transmission
`surface
`(viewer side of FIGS. 3 and 4) of the wiring substrate 40.
`line 30b and coil outer end
`While the coil inner end drawing
`line 30c are housed in the drawing
`line housing 40h
`drawing
`of the wiring substrate 40 as shown in FIG. 5, a bend 30d is
`made on each of these drawing
`lines so that these drawing
`lines go up onto the wiring substrate 40.
`system, a sec-
`[0056] Generally,
`in a power transmission
`surface.
`is disposed on the non-transmission
`ondary battery
`ion secondary battery or a lithium polymer
`As for a lithium
`typically used in cell phones and MP3
`secondary battery
`players in recent years, the temperature
`thereof during charg-
`to be about 45' C. or less due to the physical
`ing is required
`thereof. If the battery is charged at a temperature
`properties
`exceeding the temperature, a gas may occur inside the battery,
`causing the degradation of the battery and, in the worst case,
`the explosion thereof. Therefore, it is necessary to reduce the
`heating of the battery during charging. Use of the protection
`sheet 50 as a heat dissipation path reduces an increase in the
`surface.
`temperature on the non-transmission
`[0057] Also, since the inner terminal of the flat coil 30 is
`drawn from the non-transmission
`surface, the transmission
`increases the adhe-
`surface is kept flat. This advantageously
`siveness between the flat coil 30 and protection sheet (heat
`dissipation sheet) 50 to reduce the thermal contact resistance
`to facilitate heat dissipation.
`the protection sheet 50 has an
`[005S]
`In this embodiment,
`to that of the wiring substrate 40,
`external shape conforming
`thereto. The shape (area) of the protection
`but not limited
`sheet 50 may be formed so that the area of the transmission
`surface of the coil unit in contact with the internal shape (area)
`of an external case is maximized. This further enhances
`the
`heat dissipation effect.
`[0059] The spacer 70 has a hole 71 corresponding
`to the
`air-core 30a of the flat coil 30, a notch 72 that connects with
`the hole 71 and corresponds
`line housing 40h
`to the drawing
`of the wiring substrate 40, and notches 73 corresponding
`to
`the positioning holes 40e of the wiring substrate 40. The
`disposition of the notch 72 prevents (at least reduces) recesses
`formed by the thicknesses of the drawing
`and protrusions
`lines 30b and 30c of the flat coil 30 from affecting the mag-
`netic sheet 60. Also, the disposition of the notches 73 makes
`it easy to perform positioning between the wiring substrate 40
`and protection sheet 50 using the above-mentioned position-
`ing holes 40e and 50a.
`[0060] The magnetic sheet 60 has functions of receiving
`magnetic flux from the flat coil 30 and increasing
`the induc-
`tance of the flat coil 30. The material of the magnetic sheet
`may be various magnetic materials such as a soft magnetic
`material, a ferrite soft magnetic material, and a metal soft
`if only one magnetic
`magnetic material. However,
`sheet
`for the coil 30, the coil
`substance)
`is provided
`(magnetic
`characteristics with respect to this contactless power trans-
`mission largely depend on the characteristics of the one mag-
`netic sheet.
`[0061]
`In this embodiment,
`in order to increase the freedom
`degree o f choo sing from the coil characteristics
`that cannot be
`chosen with one magnetic sheet, multiple magnetic sheets are
`used. Specifically,
`in this embodiment,
`laminated magnetic
`sheets 61 and 62 having different characteristics, particularly,
`(magnetic sheets 61 and 62
`different magnetic permeabilities
`the magnetic sheet 60 as a multilayer body) are
`constitute
`provided for the coil 30. By doing so, the coil unit 22 can
`obtain different characteristics unlike a case where one mag-
`
`netic sheet is used alone or a case where two magnetic sheets
`identical characteristics are used. The first magnetic
`having
`sheet 61 and second magnetic
`sheet 62 are laminated by
`for example, using a double-sided
`them together,
`bonding
`tape.
`[0062] 3. Example Experiment with Respect to Secondary
`Coil Unit
`[0063] The coil 30 used in an experiment was formed by
`the coil wire 31 having a section as shown in FIG. 6.
`winding
`When an alternating current of I mA with a frequency of 100
`kHz was passed through the coil 30, the coil 30 alone showed
`an inductance of 6366 pH and a resistance of 0. 2340. By
`bonding at least one of the magnetic sheets 61 and 62 having
`to the flat coil 30 in combination
`to be
`different characteristics
`described later, six types of coil units (1) to (6) were obtained.
`[0064] A sheet A and a sheet B were used as magnetic
`sheets having different characteristics, particularly, different
`magnetic permeabilities. The relative magnetic permeability
`of the sheet A at an alternating-current
`frequency of 100 KHz
`is smaller than that of the sheet B.
`[0065] The coil units (1) to (6) used in the experiment are as
`follows.
`[0066] (I) A coil unit where a single sheet A is bonded to the
`surface of the coil 30
`non-transmission
`sheets A are
`(2) A coil unit where two laminated
`[0067]
`surface of the coil 30, that is,
`bonded to the non-transmission
`a coil unit where both magnetic sheets 61 and 62 are used as
`sheets A
`(3) A coil unit where a single sheet B is bonded to the
`[006S]
`surface of the coil 30
`non-transmission
`sheets B are
`(4) A coil unit where two laminated
`[0069]
`surface of the coil 30, that is,
`bonded to the non-transmission
`a coil unit where both magnetic sheets 61 and 62 are used as
`sheets B
`(5) A coil unit where a sheet A and a sheet B are
`[0070]
`surface of the
`to the non-transmission
`sequentially bonded
`coil 30, that is, a coil unit where a sheet A is used as a sheet 61
`and a sheet B is used as a sheet 62
`[0071] (6) A coil unit where a sheet B and a sheet A are
`surface of the
`to the non-transmission
`sequentially bonded
`coil 30, that is, a coil unit where a sheet B is used as a sheet 61
`and a sheet A is used as a sheet 62
`[0072] The coil units (5) and (6) are units corresponding
`to
`the coil unit (5) is a coil unit
`In