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`as) United States
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`a2) Patent Application Publication (10) Pub. No.: US 2009/0284341 Al
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` Okadaet al. (43) Pub. Date: Nov. 19, 2009
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`US 20090284341A1
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`(54) COIL UNIT AND ELECTRONIC APPARATUS
`USING TITE SAME
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`(30)
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`Int. Cl.
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`(2006.01)
`TIOIF 27/28
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`(52) US. C)e eee cee ceeceecceeeeeeeeeeeeee serene senses ceeseeeees 336/232
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`ABSTRACT
`67)
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`A coil unit includes a coil formed by winding a coil wire, a
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`wiring substrate, and a magnetic substancefor receiving mag-
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`netic lines offorce generatedbythe coil. The wiring substrate
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`includes a connection terminal connected to both endsofthe
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`coil, an external connection terminal, and a wiring pattern for
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`connecting the connection terminal and the external connec-
`tion terminal. No circuit element other than the coil
`is
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`mounted on the wiring substrate.
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`Foreign Application Priority Data
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`May 14, 2008
`(JP) ceceeeeeceseeseesceeceeneee 2008-126747
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`Publication Classification
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`(51)
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`(75)
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`Inventors:
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`Hirofumi Okada, Suwa-shi (JP);
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`Yoichiro Kondo, Chino-shi (JP)
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`4
`Add
`C
`‘orrespondence Address:
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`OLIFF & BERRIDGE, PLC
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`P.O. BOX 320850
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`ALEXANDRIA,VA 22320-4850 (US)
`.
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`SEIKO EPSON
`(73) Assignee:
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`CORPORATION,Tokyo(JP)
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`(21) Appl. No.:
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`12/429,781
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`(22)
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`Filed:
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`Apr. 24, 2009
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`NY
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`160
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`Page 1 of 23
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`GOOGLE EXHIBIT 1006
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`GOOGLE EXHIBIT 1006
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`Nov. 19,2009 Sheet 2 of 13
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`FIG. 3
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`Nov. 19,2009 Sheet 3 of 13
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`40b
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`FIG. 4
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`Nov. 19,2009 Sheet 4 of 13
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` (AREF
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`KS
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`40?
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`90F
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`Nov. 19,2009 Sheet 5 of 13
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`FIG. 6
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`at
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`H
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`Nov. 19,2009 Sheet 6 of 13
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`US 2009/0284341 Al
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`FREQUENCY-EQUIVALENT RESISTANCE CHARACTERISTIC
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`—oa
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`ed
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`Li
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`2xa io
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`c
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`goc0e
`110000
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`FREQUENCY [Hz]
`eepntA
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`70000
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`—~O-— COIL UNIT(6)
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`130000
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`—x— COIL UNIT(D)
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`ie COL UNIT(2}
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`tt COIL UNIT(3}
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`—A— COIL UNIT(4)
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`—~@— COIL UNIT(S)
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`FIG. 8
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`Page 7 of 23
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`Nov. 19,2009 Sheet 7 of 13
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`INDUCTANCE[H] 4.06E-05
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`FREQUENCY-INDUCTANCE
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`1.18E-05
`1.46E-05
`
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`f14E-05 ¢
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`11ZE-05
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`+.10E-05
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`1086-05 {==oo
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`1.04E-05
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`1.O2E-05 Pogeee
`4 90e-08be
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`50000
`70000 ©
`99000
`710000
`130000
`150000
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`FREQUENCY[Hz]
`anatasekthEtAEEETRT
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`—o— COIL UNIT(6)
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`—x— COIL UNIT(1)
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`—*— COIL UNIT(2}
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`—#— COIL UNIT(3)
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`A COIL UNIT(A)
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`—e— COIL UNIT(S)
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`FIG. 9
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`Nov. 19,2009 Sheet 8 of 13
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`MAGNETIC MAGNETIC|INDUCTANCE |RESIST-
`pe 10.131
`0.318
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`20.01728
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`21.83864
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`20.45780
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`Nov. 19,2009 Sheet 9 of 13
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`US 2009/0284341 Al
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`#2
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`N\
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`160
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`Nov. 19,2009 Sheet 10 of 13
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`US 2009/0284341 Al
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`te|
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`FIG.12
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`Page 11 of 23
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`Nov. 19
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`, 2009 Sheet 11 of 13
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`US 2009/0284341 Al
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`O9E
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`Nov. 19,2009 Sheet 12 of 13
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`FIG.14
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`Nov. 19,2009 Sheet 13 of 13
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`US 2009/0284341 Al
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`224
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`US 2009/0284341 Al
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`Nov. 19, 2009
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`COIL UNIT AND ELECTRONIC APPARATUS
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`USING THE SAME
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`BACKGROUND
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`the magnetic substance using the magnetic substance as the
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`core or maybe anair-core coil formed by winding a coil wire
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`ona plane ina spiral fashion. Useofa flat coil further ensures
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`slimming down ofthe coil unit.
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`[0011]
`In the aspect of the invention, the wiring substrate
`1. Technical Field
`[0001]
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`may have a coil housing, and the coil may be housed in the
`Several aspects of the present inventionrelates to a
`[0002]
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`coil housing. Thus, a part or all of the thickness of the coil is
`coil unit suitable for contactless power transmission and an
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`absorbed by the thickness of the substrate. This further
`electronic apparatus or the like using the coil unit.
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`ensures slimming downofthe coil unit.
`2. Related Art
`[0003]
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`In the aspect of the invention, the coil may be an
`[0012]
`[0004] There is knowncontactless power transmission that
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`air-core coil formed by winding thecoil wire on a plane, and
`uses electromagnetic induction to transmit power without
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`the inner terminal of the coil wire may be drawn from the
`using a metal contact. As applications of contactless power
`non-transmission surfaceof the coil.
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`transmission, charging of a cell phone, charging of a home
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`appliance (e.g., a handset), and the like have been proposed.
`[0013] This prevents the coil inner end drawing line from
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`[0005]
`Inrecent years, cell phonesare required to be down-
`forming protrusions on the transmission surface. This makes
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`sized further. For this reason, a coil unit for transmitting
`the transmission surface flat, thereby reducing the distance
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`power must also be further downsized, particularly, in the
`betweenthe transmission surface ofthe primarycoil and that
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`thickness dimension. lor the purpose of providing a battery
`of the secondary coil. As a result, the transmission efficiency
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`pack interface whoseuseallows charging a cell phone includ-
`is improved.
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`ing a battery pack by onlyplacing the cell phone on a power
`[0014]
`In the aspect of the invention, the coil unit may
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`transmission apparatus, JP-A-2006-311712 discloses a tech-
`further include a spacer disposed between the non-transmis-
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`nology for transmitting powerto a cell phone (1) including a
`sion surface of the coil and the magnetic substance. Thus,
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`battery pack (3) storing a protection circuit (5) and a second-
`even if the magnetic substance is not flexible, recesses and
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`ary battery (4) and a charging control circuit (6) via contact
`protrusions formed on the non-transmission surface of the
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`terminals (9) and (10) using a battery packlid (2) including a
`coil by the coil inner end drawing line are absorbed by the
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`powertransmission interface (8) anda rectifier circuit (7).
`spacer,
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`[0006]
`In JP-A-2006-311712, a coil serving as the power
`In the aspect of the invention, the magnetic sub-
`[0015]
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`transmission interface (8) is included in the battery pack lid
`stance may bea multilayer body whereaplurality ofmagnetic
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`(2) together with therectifier circuit (7). The inclusion of the
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`substances are layered. The respective magnetic substances
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`rectifier circuit (7) makes the battery pack lid (2) thicker.
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`may be an identical type of magnetic substances or different
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`Also, the battery pack lid (2) is available only as a battery
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`types of magnetic substances. If the magnetic substanceis a
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`pack; therefore,
`its use condition, that is, its flexibility in
`multilayer body where a plurality ofmagnetic substances are
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`usage is significantly restricted.
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`layered, coil characteristics (inductance, resistance, Q value,
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`or the like) that cannot be obtained with a single magnetic
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`substance are obtained. Also, since magnetic lines of force-
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`magnetic lines of force are confined within a magnetic path
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`formed by the two magnetic substances, leakage magnetic
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`flux is reduced. Therefore, a shield plate docs not always need
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`to be provided. This slims downthe coil unit.
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`[0016] The coil magnetic substance may includefirst and
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`second magnetic substances having different characteristics,
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`particularly, different magnetic permeabilities. Combination
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`of two magnetic substances having different characteristics
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`allows obtaining coil characteristics (inductance, resistance,
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`Q value, or the like) that cannot be obtained with a single
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`magnetic substance or a multilayer body where an identical
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`type ofmagnetic substancesare layered. Also, since magnetic
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`lines of forcemagnetic lines of force are confined within a
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`magnetic path formed by the two magnetic substances, leak-
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`age magnetic flux is reduced. Therefore, a shield plate does
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`not always need to be provided. This slims downthe coil unit.
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`[0017]
`In the aspect of the invention, the equivalentresis-
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`tance ofthe coil at the time whenthe first magnetic substance
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`is used as the magnetic path maybe smaller than the equiva-
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`lent resistance of the coil at the time when the second mag-
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`netic substance is used as the magnetic path, and the induc-
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`tance ofthe coil at the time whenthefirst magnetic substance
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`is used as the magnetic path may be smaller than the induc-
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`tance of the coil at the time when the second magnetic sub-
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`stance is used as the magnetic path. This allows obtaining a
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`coil having a characteristic range that cannot be obtained with
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`a coil unit where only one of the two magnetic substancesis
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`used in a single layer or multiple layers.
`
`SUMMARY
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`[0007] An advantage of an aspect of the invention is to
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`provide a coil unit that has greater flexibility in its insertion
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`position in an electronic apparatus, insertion space, and inser-
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`tion method, and an electronic apparatus using thecoilunit.
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`[0008] A coil unit according to an aspect of the invention
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`includes a coil formed by winding a coil wire, a wiring sub-
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`strate, and a magnetic substance for receiving magnetic lines
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`of force generated bythe coil. The wiring substrate includes
`
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`a connection terminal connected to both ends ofthe coil, an
`
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`external connection terminal, and a wiring pattern for con-
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`necting the connection terminal and the external connection
`terminal. No circuit element other than the coil is mounted on
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`the wiring substrate.
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`[0009] The coil unit according to the aspect ofthe invention
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`is separated from a coil control unit. This coil unit is coupled
`to the coil control unit via the external connection terminal.
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`Since the minimumelements of the coil unit are the coil,
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`wiring substrate, and magnetic substance, the coil unit is
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`downsized or slimmed down. Thus, the coil unit has greater
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`flexibility in its insertion position in an electronic apparatus,
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`insertion space, and insertion method. Depending on the
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`materials of the coil and magnetic substance,it is difficult to
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`maintain the shape of the coil unit with only the coil and
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`magnetic substance; however, integration with the wiring,
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`substrate, whichis a rigid body, allows the coil unit to main-
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`tain its shape.
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`[0010]
`Inthe aspect of the invention, the coil maybea flat
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`coil. A flat coil may be formed by winding a coil wire around
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`Page 15 of 23
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`Page 15 of 23
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`US 2009/0284341 Al
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`Nov. 19, 2009
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`[0018]
`In the aspect of the invention, the first magnetic
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`substance maybe disposed between the coil wire and the
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`second magnetic substance. Bydisposing the first magnetic
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`substance, which can reduce the equivalent resistance, near
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`the coil wire, the transmission efficiency is improved.
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`[0019]
`In the aspect of the invention, the coil unit may
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`further include a temperature detection elementand a flexible
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`substrate on which the temperature detection element
`is
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`mounted. The flexible substrate may be interposed between
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`the coil wire and the magnetic substance.
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`[0020] Thus, the coil unit is slimmed down while the tem-
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`perature detection clement is disposed in any position adja-
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`cent to the coil. If an air-core coil is used as the coil, the
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`temperature detection element maybe disposed in the air-
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`core ofthe coil. If a foreign object intrudes into the air-core
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`having a high magnetic flux density ofthe air-core coil, heat-
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`ing caused by an eddy current generated by the foreign object
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`becomes extremelysignificant. The temperature of the for-
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`eign object orthatofthe coil is detected using the temperature
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`detection element, suchas a thermistor,that ismounted on the
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`flexible substrate and disposedin theair-core ofthe air-core
`coil.
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`[0021] Anelectronic apparatus according to another aspect
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`of the invention includes an insertion part into which the
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`above-mentioned coil unit is to be inserted and a main body
`terminal to be connected to the external connection terminal
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`of the coil unit. Since the coil unit is downsized or slimmed
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`down,it has greater flexibility in its insertion position in the
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`insertion part of the electronic apparatus and inits insertion
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`space. Also, the coil unit hasgreaterflexibility in its insertion
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`method suchas slot-in or insertion into a lid such as a battery
`lid.
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`BRIEF DESCRIPTION OF THE DRAWINGS
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`FIG. 13 is a schematic block diagram ofthe primary
`[0035]
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`and secondary coil units shown in FIG. 12 and control units
`connected thereto.
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`FIG. 14 is a schematic perspective view showing a
`[0036]
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`main part of a modification ofa coil unit.
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`[0037]
`FIG. 15 is a drawing showing a modification where
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`the secondary coil unit can be attached to or detached from an
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`electronic apparatus.
`DESCRIPTION OF EXEMPLARY
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`EMBODIMENT
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`[0038] Now, a preferred embodimentofthe invention will
`be describedin detail. The embodimentdescribed below does
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`not unduly limit the invention as set forth in the appended
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`claims. Also, not all the configurations described in the
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`embodiment are essential as means for solving the above-
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`mentioned problems.
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`1. Charging System
`[0039]
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`FIG.1 isadrawing schematically showing a charger
`[0040]
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`10, whichis also an example ofan electronic apparatus, and
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`a cell phone 20, which is an example of an electronic appa-
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`ratus changedby the charger 10. FIG. 1 showsthe cell phone
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`20 to be transversely placed on the charger 10. The cell phone
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`20 is chargedby the charger 10 by means ofcontactless power
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`transmission using, an electromagnetic induction action pen-
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`erated between a coil ofa coil unit 12 of the charger 10 and a
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`coil of a coil unit 22 of the cell phone 20.
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`[0041] The charger 10 and cell phone 20 may each have a
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`positioning structure. For example, the charger 10 may have
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`a positioning protrusion protruding out ofthe outer surface of
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`the case thereof. On the other hand, the cell phone 20 may
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`have a positioning recess on the outer surface of the case
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`thereof. By using such positioningstructures, the coil unit 22
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`of the cell phone 20 is at least disposed in a position opposed
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`to the coil unit 12 of the charger 10.
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`[0022] Theinvention will be described with reference to the
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`[0042] As schematically shown in FIG. 2, poweris trans-
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`accompanying drawings, wherein like reference numerals
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`mitted from the charger 10 to the cell phone 20 by electro-
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`representlike elements.
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`magnetically coupling a primary coil L1 (powertransmission
`FIG. 11s adrawing schematically showing a charger
`[0023]
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`coil) included in the charger 10 and a secondary coil L2
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`and an electronic apparatus charged by the charger, such as a
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`(powerreception coil) included in the cell phone 20 and thus
`cell phone.
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`forming a powertransmission transformer. This realizes con-
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`FIG. 2 is a drawing showing an example of a con-
`[0024]
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`tactless power transmission. Note that FIG. 2 shows an
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`tactless power transmission method.
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`example of electromagnetic coupling between the primary
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`FIG. 3 is a drawing schematically showing a sec-
`[0025]
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`coil L1 and secondary coil L2 and that another type of elec-
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`ondary coil unit.
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`tromagnetic coupling where magnetic lines of forcemagnetic
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`FIG. 4 is an exploded perspective view schemati-
`[0026]
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`lines of force are formed in a waydifferent from that in FIG.
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`cally showing the secondary coil unit.
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`2 may be adopted.
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`[0027]
`FIG. 5isa drawing schematically showing a section
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`[0043]
`2. Coil Unit of Cell Phone 20
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`taken along line V-Vof FIG.3.
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`FIG. 3 is a drawing schematically showingthe coil
`[0044]
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`[0028]
`FIG.6 is a sectional view ofa coil wire.
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`unit 22 (secondary coil unit) of the cell phone 20. FIG.4 is an
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`[0029] FIG. 7 isa drawing showing a form whereasecond-
`exploded perspective view schematically showing the coil
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`ary coil unit and a control unit are electrically connected.
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`unit 22 of the cell phone 20. In FIGS. 3 and 4, the non-
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`[0030]
`FIG. 8 is a graph showing [requency-equivalent
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`transmission surface of the coil unit 22 opposite to the trans-
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`resistance characteristics obtained from an experiment.
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`mission surface thereof opposed to the coil unit 12 of the
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`FIG. 9 is a graph showing frequency-inductance
`[0031]
`charger 10 in FIG. 1 is seen from above. The transmission
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`characteristics obtained from the experiment.
`surfacesrefer to the respective surfaces ofthe coil unit 22 and
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`FIG. 10 is a table where values at a frequency of
`[0032]
`the coil unit 12 opposed to each other in FIG. 1 and the
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`100,000 Hz extracted from characteristics shown in the
`non-transmission surfaces refer to the respective surfaces
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`above-mentioned graphs are organized.
`opposite to the transmission surfaces of the coil unit 12 and
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`FIG. 11 is an exploded perspective view schemati-
`[0033]
`coil unit 22. FIG. 5 is a drawing schematically showing a
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`cally showing the primary coil unit.
`section taken along line V-V of FIG. 3. FIG.6 is a sectional
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`[0034]
`FIG. 12 is a schematic perspective view of a power
`view showing an example of a coil wire. FIG. 7 shows a form
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`transmission apparatus where the primary coil unit and a
`in which the coil unit 22 and a control unit (coil control unit)
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`control unit are electrically connected.
`100 are electrically coupled.
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`Page 16 of 23
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`Page 16 of 23
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`

`

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`US 2009/0284341 Al
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`
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`Nov. 19, 2009
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`limited thereto. Hereafter, the coil unit 22 according to this
`[0045] Thecoil unit 22 includes acoil 30, a wiring substrate
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`embodimentwill be described taking theflat coil 30 having an
`40, anda magnetic substance 60 as minimum elements.In this
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`air-core 30a (see FIGS. 4, 5) as an example.
`embodiment,a coil housing 40a maybe formed on the wiring
`substrate 40 so that the transmission surface of the coil 30 is
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`[0051] As described above, theflat coil 30 is housed in the
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`positioned onthe back surface ofthe wiring substrate 40. For
`coil housing 40a provided on the wiring substrate 40. This
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`example, the coil housing 40a is a hole that penetrates the
`allows slimming down the coil unit 22 byapart or all of the
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`wiring substrate 40 in the thickness direction. Also, in this
`thickness H (see FIG. 6) of the flat coil housed in the coil
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`embodiment, a protection sheet 50 for protecting the trans-
`housing 40a. This also makesit easy to make the transmission
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`mission surface of the coil 30 may be provided on the back
`surface of the flat coil 30 flush with the adjacent surface.
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`surface of the wiring substrate 40 shownin FIG.4.
`Actually, in this embodiment, no recesses or protrusions are
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`[0046] The wiring substrate 40 is provided with connection
`formed on the protection shect 50. Also, the coil housing 40a
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`terminals 404 to which both the ends of the coil 30 are con-
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`has a shape corresponding the external shape ofthe flat coil
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`nected, external connection terminals 41 and 42, and wiring
`30. Thus, ifthe flat coil 30 is only housedin the coil housing
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`patterns 41a and 42a. Nocircuit element other than the coil 30
`40a, the flat coil 30 is positioned in the wiring substrate 40.
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`is mounted on the wiring substrate 40. The external connec-
`This facilitates positioning. As shown in I'IG.4, the wiring
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`tion terminals 41 and 42 are terminals used when connecting
`substrate 40 has multiple positioning holes 40e, and the pro-
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`the coil unit 22 to an external apparatus suchas the control
`tection sheet 50 has multiple positioning holes 50a (only one
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`unit 100 shown in FIG. 7. The wiring patterns 41a and 42a
`is shownin FIG. 4).
`connect between the connection terminals 406 and external
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`[0052] The coil unit 22 may be assembled, for example,
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`connection terminals 41 and 42. While the wiring patterns
`usingfixtures. First, the pins ofthe fixtures are passed through
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`41a and 42a maybe formedonthefront surface (the surface
`the positioning holes 50a of the protection sheet 50 and the
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`on whichthe terminals 404, 41a, and 42a are formed) of the
`positioning holes 40e of the wiring substrate 40, and then the
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`wiring substrate 40 shownin FIG.4, these patterns may be
`protection sheet 50 having a single-sided tape and wiring
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`provided on the back surface of the wiring substrate 40 and
`substrate 40 are laminated. Next, the coil 30 is disposed in the
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`connected to the terminals 404, 41a, and 42a via through-
`coil housing 40a ofthe wiring substrate 40 and bondedto the
`holes.
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`protection sheet 50. Then, the magnetic sheet 60 is bonded to
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`Inthis embodiment, as shownin FIG.7, the second-
`[0047]
`the wiring substrate 40 with the spacer 70 therebetween in
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`ary coil unit 22 is separated from the secondary control unit
`such a mannerthat the spacer 70 covers the coil 30. Finally,
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`both ends of the flat coil 30 are soldered to the connection
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`100. The secondary coil unit 22 is coupled to the secondary
`control unit 100 via the external connection terminals 41 and
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`terminals 406 of the wiring substrate 40. This completes the
`42. Since the minimum elements ofthe coil unit 22 are the coil
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`coil unit 22. While the protection sheet 50 is a sheet for
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`30, wiring substrate 40, and magnetic substance 60, the coil
`protectingat least the flat coil 30, it covers both the transmis-
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`unit 22 is downsized or slimmed down.Thus,the coil unit 22
`sion surfaces of the wiring substrate 40 and coil 30 in this
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`has greaterflexibility in its insertion position in the electronic
`embodiment. The protection sheet 50 may have a hole in a
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`apparatus 20, insertion space, and insertion method. Depend-
`position correspondingto the air-core 30a.
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`ing on the materials of the coil 30 and magnetic sheet 60, the
`[0053] The flat coil 30 has a coil inner end drawingline 306
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`coil unit 22 is difficult to maintain its shape with only the coil
`for drawing the inner end of the coil and a coil outer end
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`30 and magnetic sheet 60; however, integration with the wir-
`drawingline 30c for drawing the outer end thereof. As shown
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`ing substrate 40, which is a rigid body, allows the coil unit 22
`in FIG. 4, the coil inner end drawing line 304 is preferably
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`drawnfrom the non-transmission surface ofthe flat coil 30.
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`to maintain its shape.
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`[0048] The control unit 100 shownin FIG. 7 includes a
`This prevents the coil inner end drawing line 304 fromform-
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`substrate 110 on which various electronic components for
`ing protrusions on the transmission surface. This keeps the
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`transmission surface flat, as well as reduces the distance
`drive-controlling the secondary coil 130 are mounted. The
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`substrate 110 is provided with external connection terminals
`between the respective transmission surfaces of the primary
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`111 and 112electrically connected to the external connection
`coil L1 and secondarycoil L2 shownin FIG.2. Asa result, the
`terminals 41 and 42 formed on the substrate 40 of the sec-
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`transmission e[liciency is increased.
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`ondary coil unit 22. The control unit 100 will be described
`[0054] The wiring substrate 40 has a drawing line housing
`later.
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`40h connecting with the coil housing 40a (see FIGS. 3 to 5).
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`[0049] The coil 30is, for example,a flat coil. The magnetic
`The drawing line housing 40/ is intended to house the coil
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`substance 60 takes the shape ofa sheet or a plate. Hereafter, a
`inner end drawingline 306oftheflat coil 30 and coil outer end
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`shect-shaped magnetic substance will be also referred to as a
`drawing line 30c thereof. While onlythe coil outer end draw-
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`magnetic sheet. The magnetic sheet 60 is provided in such a
`ing line 30c is shownin FIG.5, the same goes for the coil
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`mannerthat it is opposed to the non-transmission surface of
`inner end drawingline 306. Since the drawing lines 306 and
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`the flat coil 30. In this embodiment, the magnetic sheet 60 is
`30c are housed in the drawing line housing 404, that area is
`bondedto the non-transmission surface ofthe flat coil 30 and
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`slimmed down by the thicknesses of the drawing lines 306
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`the wiring substrate 40 with a spacer 70 (e.g., double-sided
`and 30c. Also, as shownin I'lG.4, the drawing lines 305 and
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`tape) therebetween.
`30c (only the drawing line 30c is shown in I'IG.5) are bent
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`relatively gently and then go up onto the wiring substrate 40.
`[0050] The flat coil 30 is not limited to any particular coil if
`This reduces wire breaks.
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`it is a flat coil. For example, an air-core coil formed by
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`winding a single-conductor or multi-conductor, coated coil
`[0055] The coil inner end drawing line 304 and coil outer
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`wire on a plane may beused. In this embodiment, a coil
`end drawing line 30c are drawnto the contact terminal 406
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`formed by winding a single-conductor coil wire 31, whose
`serving as connection terminals of the coil 30 and then elec-
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`section is a rectangle with a width W anda height H, on a
`trically connected to the patterns on the wiring substrate 40 by
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`plane as shownin FIG.6 is used; however, the section is not
`soldering 40g as shown in FIGS. 3 and 5. The contact termi-
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`Page 17 of 23
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`Page 17 of 23
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`US 2009/0284341 Al
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`Nov. 19, 2009
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`netic sheet is