throbber

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`a2) United States Patent
`US 9,252,611 B2
`(0) Patent No.:
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`Feb.2, 2016
`(45) Date of Patent:
`Lee et al.
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`US009252611B2
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`(54) MAGNETIC FIELD SHIELDING SHEET FOR
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`A WIRELESS CHARGER, METHOD FOR
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`
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`MANUFACTURING SAME, AND RECEIVING
`APPARATUS FOR A WIRELESS CHARGER
`
`
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`USING THE SHEET
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`(72)
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`*)
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`Notice:
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`(71) Applicant: AMOSENSE CO., LTD., Cheonan-si
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`(KR)
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`Inventors: Dong Hoon Lee, Yongin-si (KR); Kil
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`Jae Jang, Seoul (KR)
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`(73) Assignee: AMOSENSE CO., LTD.(KR)
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`1)
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`Subject to any disclaimer, the term of this
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`patent is extended or adjusted under 35
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`U.S.C. 154(b) by 36 days.
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`(58) Field of Classification Search
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`CPC o.. H02J 5/005; H02J 7/025; H02J 7/0042;
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`H02J 7/355; HOF 27/362; HO1F 27/365
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`USPC wee 320/107, 108, 114; 336/84 R, 84 C
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`See application file for complete search history.
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`References Cited
`U.S. PATENT DOCUMENTS
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`(56)
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`4,774,148 A *
`
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`5,097,373 A *
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`9/1988 Goto we B32B 15/04
`428/607
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`
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`
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`3/1992 Yuki wee HOILF 3/02
`360/125.01
`
`
`
`FOREIGN PATENT DOCUMENTS
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`
`
`(Continued)
`
`
`
`JP
`
`KR
`
`
`2006269536
`1020030013831
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`10/2006
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`2/2003
`
`
`(Continued)
`OTHER PUBLICATIONS
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`International Search Report—PCT/KR2012/011256 dated Mar. 18,
`2013.
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`Primary Examiner — Edward Tso
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`(74) Attorney, Agent, or Firm — Cantor Colburn LLP
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`(57)
`ABSTRACT
`
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`Provided are a magnetic field shield sheet for a wireless
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`charger, which blocksan effect of an alternating-current mag-
`
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`netic field generated when a charger function for a portable
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`mobile terminal device is implementedin a non-contact wire-
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`less manner on a main bodyof the portable mobile terminal
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`device and exhibits excellent electric power transmission effi-
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`ciency, a method of manufacturing the sheet, and a receiver
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`for the wireless charger by using the sheet. The sheet
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`includes: at least one layer thin magnetic sheet made of an
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`amorphousribbon separated into a plurality offine pieces; a
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`protective film that is adhered on one surface of the thin
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`magnetic sheetvia a first adhesive layer provided on oneside
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`of the protective film; and a double-sided tape that is adhered
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`on the other surface of the thin magnetic sheet via a second
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`adhesive layer provided on oneside ofthe double-sided adhe-
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`sive tape, wherein gaps amongthe plurality of fine pieces are
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`filled by somepartsofthe first and second adhesivelayers, to
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`thereby isolate the plurality of fine pieces.
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`18 Claims, 11 Drawing Sheets
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`(22)
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`(21) Appl. No.:
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`PCTFiled:
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`(86) PCT No.:
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`§ 371 ()Q),
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`(2) Date:
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`(87) PCT Pub. No.: WO2013/095036
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`PCT Pub. Date: Jun. 27, 2013
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`14/366,439
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`Dec. 21, 2012
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`PCT/KR2012/011256
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`Jun. 18, 2014
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`(65)
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`(30)
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`Prior Publication Data
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`May7, 2015
`US 2015/0123604 Al
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`Foreign Application Priority Data
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`(KR) wees 10-201 1-0138987
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`Dec. 21,2011
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`Int. Cl.
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`HOIM 10/44
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`HOIM 10/46
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`(51)
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`(2006.01)
`(2006.01)
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`(Continued)
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`(52) U.S. CL.
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`CPC wee HO02J 7/0042 (2013.01); B32B 37/12
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`(2013.01); B32B 37/18 (2013.01);
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`(Continued)
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`Page | of 26
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`SAMSUNG EXHIBIT1013
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`SAMSUNG EXHIBIT 1013
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`US 9,252,611 B2
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`(56)
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`References Cited
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`Int. Cl.
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`HO02J 7/00
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`HOIF 38/14
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`HOIF 27/36
`B32B 3712
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`B32B 37/18
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`B32B 38/00
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`HO02J 7/02
`FOREIGN PATENT DOCUMENTS
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`KR
`6/2003
`HO25 5/00
`102003005 1394
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`KR
`11/2003
`(52) US. Cl.
`1020030086 122
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`KR
`3/2010
`CPC veeeeeeee B32B 38/0004 (2013.01); HOIF 27/365
`1020100031139
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`(2013.01); HOF 38/14 (2013.01); H027 5/005=KR 101399024 5/2014
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`(2013.01); HO2J 7/025 (2013.01)
`* cited by examiner
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`U.S. PATENT DOCUMENTS
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`5,227,727 A *
`7/1993 Segawa veces: GOR 33/36
`5,680,046 A * 10/1997 Frederick
`GOIR33/420
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`rederick wv...
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`;
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`324/318
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`U.S. Patent
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`Feb. 2, 2016
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`Sheet 1 of 11
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`US 9,252,611 B2
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`FIG. 2
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`10a
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`7
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`U.S. Patent
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`Feb. 2, 2016
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`Sheet 2 of 11
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`US 9,252,611 B2
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`FIG. 3
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` ji
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`; ])
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`8a 3b 3c 3d 3e 3f=20
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`FIG. 4
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`FIG. 5
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`Aa
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`Ab
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`31
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`32
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`33
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`4
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`U.S. Patent
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`Feb. 2, 2016
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`Sheet 3 of 11
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`US 9,252,611 B2
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`FIG. 6
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`U.S. Patent
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`Feb. 2, 2016
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`Sheet 4 of 11
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`US 9,252,611 B2
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`FIG. 7
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`PREPARE AMORPHOUS RIBBON
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`CUT THE AMORPHOUS RIBBON INA SHEET FORM
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`O14
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`S12
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`HEAT TREAT AMORPHOUS RIBBON SHEET $13
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`LAMINATE RIBBON SHEET BETWEENPROTECTIYV
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`EFILM AND DOUBLE-SIDED TAP AND THEN
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`PERFORM FLAKE TREATMENT
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`014
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`PERFORMLAMINATION TREATMENT
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`~$15
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`S16
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`START
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`STAMP LAMINATE SHEET
`IN A DESIRED SIZE AND SHAPE
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`US 9,252,611 B2
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`FIG. 8
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`Feb. 2, 2016
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`Sheet 6 of 11
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`US 9,252,611 B2
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`Re
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`Roe
`SSSISSTST
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`FIG. 11
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`-
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`400
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`210
`200
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`220
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`Sheet 7 of 11
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`US 9,252,611 B2
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`FIG. 12
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`500
`yo
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`250
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`200
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`+~ 240
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`US 9,252,611 B2
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`FIG. 14A
`FIG. 14B
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`FIG. 15A
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`35
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` GGQQ J.QQAAAAAAAAAAA
`WMA
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`398 35c
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`35b
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`FIG. 15B
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`FIG. 17
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`US 9,252,611 B2
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`t
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`FIG. 19
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`BATTERY
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`TRANSMISSION DEVICE
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`Page 13 of 26
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`US 9,252,611 B2
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`
`1
`MAGNETIC FIELD SHIELDING SHEET FOR
`
`
`
`
`
`
`
`
`
`A WIRELESS CHARGER, METHOD FOR
`
`
`
`
`MANUFACTURING SAME, AND RECEIVING
`APPARATUSFOR A WIRELESS CHARGER
`
`
`
`
`USING THE SHEET
`
`
`
`
`
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`The present invention relates to a magnetic field shield
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`sheet for a wireless charger, a method of manufacturing the
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`magnetic field shield sheet, and a receiver for the wireless
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`charger by using the magnetic field shield sheet, and more
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`particularly to, a magnetic field shield sheet for a wireless
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`charger, which blocksan effect of an alternating-current mag-
`
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`
`
`
`
`
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`netic field generated when a charger function for a portable
`
`
`
`
`
`
`mobile terminal device is implementedin a non-contact wire-
`
`
`
`
`
`
`
`less manner on a main bodyof the portable mobile terminal
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`
`
`
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`
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`device and exhibits excellent electric powertransmission effi-
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`ciency, a method of manufacturing the magnetic field shield
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`sheet, and a receiver for the wireless charger by using the
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`magnetic field shield sheet.
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`2
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`coil and a magnetic sheet has been proposed. In the proposed
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`structure, a magnetic body or a magnetic sheet is used as a
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`core material to strengthen the coupling between primary and
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`secondary coils.
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`Meanwhile,
`if a power transmission speed increases,
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`defects between adjacent transformers, as well as defects
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`caused by heat from the surrounding components, may be
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`likely to occur. That is, in the case that the planar coils are
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`used, the magnetic flux passing through the planar coils is
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`connectedto a substrate or the like inside an electronic device,
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`an internalportion ofthe electronic device may be heated due
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`to eddy currents caused by electromagnetic induction. As a
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`result, large power cannot be transmitted and thus a time-
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`consuming problem may be caused for charging the elec-
`tronic device.
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`To cope with this problem, a magnetic body or a magnetic
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`sheet was used as a shielding member on the back of the
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`substrate. In order to obtain a sufficient shielding effect, as the
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`magnetic body or the magnetic sheet may have the larger
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`magnetic permeability, and the larger area and thickness, a
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`moreeffective shielding effect can be obtained.
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`In general, a magnetic body such as an amorphousribbon,
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`a ferrite sheet, or a polymer sheet containing magnetic pow-
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`der is used as the magnetic field shield sheet. An effect of
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`focusing a magnetic field for improving magnetic field
`As methods of charging secondary batteries mounted in
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`shielding performance and additional features may be good in
`electronic equipment such as portable terminals and video
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`the order of amorphousribbons, a ferrite sheet, and a polymer
`cameras, there are two types of charging methods, i.e., a
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`sheet containing magnetic powder, with high magnetic per-
`contact type charging method and a non-contact type charg-
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`meability.
`ing method. The contact type charging methodcarries out a
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`In the case of a powerreception device of a conventional
`charging operation by making an electrode of a powerrecep-
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`non-contact type charging system, a magnetic body or a mag-
`tion device in direct contact with an electrode of a power
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`netic sheet with high magnetic permeability and large volume
`feeding device.
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`is disposed on the opposite surface to a primary coilside,i.e.,
`The contact type charging method is commonly usedin a
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`on the surface of a secondary coil, for reinforcement of a
`wide range of applications, since a structure of a device
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`coupling for improving transmission efficiency, and for
`implementing the contact type charging method is simple.
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`improving a shielding performance for suppression of heat
`However,
`in association with miniaturization and weight
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`generation. Accordingto this arrangement,fluctuationsin the
`reduction of electronic equipment, various electronic devices
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`inductance ofthe primary coil becomelarge, and an operation
`become light in the weight thereof, and accordingly a low
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`condition of a resonantcircuit is shifted from a resonance
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`contact pressure between electrodes of the power reception
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`condition at whichasufficient effect can be exhibited accord-
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`device and the power feeding device may cause problems
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`such as chargefailure chargeerror. Further, secondary batter-
`ing to a relative positional relationship between the magnetic
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`ies are weak at heat, which needs to prevent the temperature
`body andthe primary coil.
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`rise of the batteries, and to pay attention to a circuit design so
`Korean Patent Application Publication No. 10-2010-31139
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`as not to cause overcharge and overdischarge. To cope with
`provides a powerreception device for improving a resonance
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`these problems, a non-contact type charging methodis being
`performance and also suppressing heat generation to solve
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`considered in recent years.
`the aforementioned problems, and proposes a technique of
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`The non-contact
`type charging method is a charging
`enabling large transmission power and shortening charge
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`method using an electromagnetic induction principle in
`time, through an the electronic device and a powerreception
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`which coils are mounted at both sides of the power reception
`system using the power reception device.
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`device and the powerfeeding device.
`In other words, according to Korean Patent Application
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`A non-contact type charger can be miniaturized by putting
`Publication No. 10-2010-31139, a composite magnetic body
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`a ferrite core to be in a magnetic core and winding coils
`including a plurality of magnetic sheets magnetic ribbonsare
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`aroundthe ferrite core. Furthermore, for miniaturization and
`arrangedat at least one location between a spiral coil a power
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`reduction in thickness, a technique of forming a resin sub-
`reception-side spiral coil: a secondary coil and a secondary
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`strate by mixing ferrite powder and amorphous powder and
`battery, and betweena rectifier and thespiral coil, to thereby
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`mounting a coil and the like on the resin substrate, has been
`prevent a magnetic flux generated from the powerreception-
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`proposed. However, in the case thata ferrite sheet is processed
`sidespiral coil from interlinking a circuit board and a second-
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`thinly, the thinly processedferrite sheet may be easily broken
`ary battery, and to thereby suppress noise and heat generation
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`and weak in impact resistance. As a result, there have been
`caused by an induced electromotive force electromagnetic
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`induction, and the amountoffluctuation of inductance in the
`problemsthat defects have occurred in the power reception
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`device due to a fall or collision of the non-contact type
`primary coil is controlled due to presence or absence of the
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`charger.
`secondary coil to thus enhance a resonance performanceof a
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`Further, in order to reduce thickness of a powerreception
`resonant circuit constituted by the primary coil and to thereby
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`portion of an electronic device in responseto reduction in the
`effectively control oscillation.
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`thickness of the electronic device, a planar coil that is formed
`The composite magnetic body is set so that first magne-
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`by printing a metal powder paste as a coil have been
`toresistance ofafirst magnetic sheet adjacentto thespiral coil
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`employed. A structure of strengthening a coupling of a planar
`is less than or equal to 60, second magnetoresistance of a
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`TECHNICAL FIELD
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`BACKGROUND ART
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`US 9,252,611 B2
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`solving the heat generation problem due to shields and
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`improving the wireless charging efficiency. Thus, the present
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`inventors recognized that inductance (magnetic permeabil-
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`ity) is less reduced and magnetoresistanceis greatly reduced,
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`although an amorphousribbon undergoesflakesin the case of
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`the amorphous ribbon, and thus a quality factor (Q) of the
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`secondary coil is increased,
`to thereby reach the present
`invention.
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`DISCLOSURE
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`Technical Problem
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`3
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`second magnetic sheet laminated on the first magnetic sheetis
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`greater than or equal to 100, and a value of the second mag-
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`netoresistance divided by thefirst magnetoresistance is equal
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`to or greater than 1.0.
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`Thefirst magnetic sheet is prepared by bonding polycar-
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`bonate resins on both surfaces of a first amorphousribbon by
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`using adhesive layers, respectively, and the second magnetic
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`sheet is prepared by bonding polycarbonate resins on both
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`surfaces of a second amorphousribbon with large relative
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`permeability by using adhesive layers, respectively. Then, the
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`first magnetic sheet and the second magnetic sheet are inte-
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`grally bonded via an adhesive layer.
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`Meanwhile,the ferrite sheet or a polymersheet containing
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`magnetic powderhas the magnetic permeability a little lower
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`To solve the above problemsor defects, it is an object ofthe
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`than the amorphousribbon, and thus in order to improve the
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`present invention to provide a magnetic field shield sheet for
`performanceof such low magnetic permeability, thickness of
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`a wireless charger, which greatly reduces a loss due to eddy
`the ferrite sheet or a polymer sheet becomes large compared
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`currents by a flake treatment process of an amorphousribbon,
`to the thin amorphousribbonof several tens um. Therefore,it
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`to thereby block an effect ofa magneticfield influencing upon
`is difficult to respond to a thinning tendency of terminals.
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`a main body anda battery of a portable mobile terminal
`Further, in the case of amorphous ribbon with high mag-
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`device and simultaneously to increase a quality factor (Q) of
`netic permeability, the ribbon itself is a metal thin plate, and
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`a secondary coil, and to thus exhibit excellent electric power
`thusthere is no burden on thickness ofthe amorphousribbon.
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`transmission efficiency, a method of manufacturing the mag-
`However, whenan alternating-current magneticfield accord-
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`netic field shield sheet, and a receiver for the wireless charger
`ing to frequency of 100 kHz used for powertransmission is
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`by using the magnetic field shield sheet.
`applied to the amorphousribbon, functionality of applica-
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`tions may be reduced due to an influence of eddy currents of
`It is another object of the present invention to provide a
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`the ribbon surface, or problems ofreducing wireless charging
`magnetic field shield sheet for a wireless charger, whichfills
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`efficiency and causing heat generation may occur.
`a gap betweenfine pieces of an amorphousribbon through a
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`Co-based or Fe-based amorphous ribbons can increase
`flake treatment process of the amorphousribbon and then a
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`surface resistance slightly, through heat treatment. However,
`compression laminating process with an adhesive, to thereby
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`in the case that a processing treatment such asaflake treat-
`prevent water penetration, and which simultaneously sur-
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`ment process of reducing a surface area of the ribbon is
`rounds all surfaces of the fine pieces with an adhesive (or a
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`performedin order to further reduce the eddy currenteffects,
`dielectric) to thus mutually isolate the fine pieces to thereby
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`the magnetic permeability is significantly degraded and the
`promote reduction of eddy currents and prevent shielding
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`function as the shield sheet is greatly degraded.
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`performance from falling, and a manufacturing method
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`Also, most of wireless chargers employastructure of
`thereof.
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`adopting permanent magnets that assist an alignment with a
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`It is still another object of the present invention to provide
`powerreceiver in a powertransmitter for powertransmission,
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`a magnetic field shield sheet for a wireless charger, which
`in orderto increase the powertransferefficiency ofthe charg-
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`establishes a shape ofa shield sheet into a shape similarto that
`ers to the maximum. A magnetization or saturation phenom-
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`enon occurs in a thin shield sheet due to a direct-current
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`of a secondary coil of a receiving device for a wireless
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`charger, to thereby exhibit high powertransmissionefficiency
`magneticfield of the permanent magnets, to thereby decrease
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`even though a small number of nanocrystalline ribbons are
`the performance of the chargers or sharply decreasing the
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`used, and a powerreception device using the magnetic field
`powertransmission efficiency.
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`shield sheet.
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`Accordingly, in the case of the conventional chargers, the
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`thickness ofthe shield sheet must be quite thick in the order of
`Itis yet another object ofthe present invention to provide a
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`0.5 T or higher, in orderto indicate shielding features without
`magnetic field shield sheet for a wireless charger, which
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`being affected by the permanent magnets, and to maintain
`sequentially performs a flake treatment process and a lami-
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`high powertransmission efficiency, which may cause a major
`nating process by using a roll-to-roll method,
`to thereby
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`obstacle on slimmingof portable terminals.
`achieve a sheet molding process to thus maintain original
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`A voltage induced in a secondary coil of a wireless charger
`thickness of the sheet and to thus exhibit high productivity
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`is determined by the Faraday’s law and the Lenz’s law, and
`and inexpensive manufacturing costs.
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`thus it is more advantageous to have the greater amount of
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`magnetic flux linked with the secondary coil in order to obtain
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`a high voltage signal. The amount of the magnetic flux
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`becomes large as the amount of a soft magnetic material
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`contained in the secondary coil becomeslarge and the mag-
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`netic permeability ofthe material becomeshigh.In particular,
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`since the wireless chargers essentially employ a non-contact
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`powertransmission system, a magnetic field shield sheet in
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`which the secondary coil is mounted is needed to be made of
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`a magnetic material with high permeability, in order to focus
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`wireless electromagnetic waves made from the primary coil
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`of a powertransmission device, on the secondary coil of a
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`powerreception device.
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`Conventional magnetic field shield sheets for wireless
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`chargers do notpresent solutionsfor attaining the thin film but
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`To accomplish the above and other objects of the present
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`invention, according to an aspect of the present invention,
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`there is provided a magnetic field shield sheet for a wireless
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`charger, the magnetic field shield sheet comprising:
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`at least one layer thin magnetic sheet made of an amor-
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`phousribbon separated into a plurality of fine pieces;
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`a protective film that is adhered on one surface of the thin
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`magnetic sheetvia a first adhesive layer provided on oneside
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`of the protective film; and
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`a double-sided tape that is adhered on the other surface of
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`the thin magnetic sheet via a second adhesive layer provided
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`on one side of the double-sided adhesive tape,
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`Technical Solution
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`Page 15 of 26
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`6
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`In addition, the present invention provides a magnetic field
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`shield sheet for a wireless charger, whichfills a gap between
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`fine pieces of an amorphousribbon through a flake treatment
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`process of the amorphous ribbon and then a compression
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`laminating process with an adhesive, to thereby prevent water
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`penetration, and which simultaneously surrounds all surfaces
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`of the fine pieces with an adhesive (or a dielectric) to thus
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`mutually isolate the fine pieces to thereby promote reduction
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`of eddy currents and prevent shielding performance from
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`falling, and a manufacturing methodthereof Asa result, all
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`surfaces of the fine pieces are surroundedby an adhesive (or
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`a dielectric material) to thereby prevent water from penetrat-
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`ing into the amorphousribbon andto thus prevent the amor-
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`phousribbon from being oxidized and changes in appearance
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`and characteristics from being deteriorated.
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`Moreover, the present invention provides a magneticfield
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`shield sheet for a wireless charger, which establishes a shape
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`of a shield sheet into a shape similar to that of a coil of a
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`receiving device for a wireless charger, to thereby exhibit a
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`high powertransmission efficiency or equal power transmis-
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`sion efficiency while lowering thickness ofthe magneticfield
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`shield sheet to be equal to or less than 0.3 mm, even though a
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`small number of nanocrystalline ribbons are used, and a
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`powerreception device using the magnetic field shield sheet.
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`In addition, the present invention provides a magnetic field
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`shield sheet for a wireless charger, which sequentially per-
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`formsa flake treatment process and a laminating process by
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`using a roll-to-roll method, to thereby achieve a sheet mold-
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`ing process to thus maintain original thickness of the sheet
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`and to thus exhibit high productivity and inexpensive manu-
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`facturing costs.
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`5
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`wherein gaps amongtheplurality offine piecesare filled by
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`someparts ofthe first and second adhesivelayers, to thereby
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`isolate the plurality of fine pieces.
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`According to another aspect of the present invention, there
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`is provided a method ofmanufacturing a magneticfield shield
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`sheet for a wireless charger, the method comprising the steps
`of:
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`adhering a protective film and a double-sided tape formed
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`of a release film on an exposed surface of the double-sided
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`tape, on both sides of at least one layer thin magnetic sheet
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`made of an amorphous ribbon, to thereby form a laminate
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`sheet;
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`performinga flake treatment process of the laminate sheet
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`to thus separate the thin magnetic sheet into a plurality of fine
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`pieces; and
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`laminating theflake treated laminate sheet, to thusfill some
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`parts of first and second adhesive layers provided in the pro-
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`tective film and the double-sided tape into gaps among the
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`plurality of fine pieces,
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`a protective film that is adhered on onesurface of the thin
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`magnetic sheetvia a first adhesive layer provided on one side
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`of the protective film; and
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`a double-sided tape that is adhered on the other surface of
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`the thin magnetic sheet via a second adhesive layer provided
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`on one side of the double-sided adhesive tape, together with
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`flattening and thinning of the laminate sheet, and to thereby
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`isolate the plurality of fine pieces.
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`Accordingto still another aspect of the present invention,
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`there is provided a reception device for a wireless charger that
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`charges a secondary battery by an electromagnetic induction
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`method from a transmission device for the wireless charger,
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`the reception device comprising:
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`a secondary coil that receives a wireless high frequency
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`signal transmitted by the electromagnetic induction method
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`FIG. 1 is an exploded perspective view showing a magnetic
`from the transmission device; and
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`field shield sheet for a wireless charger according to the
`a magnetic field shield sheet that is disposed between the
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`present invention.
`secondary coil and the secondary battery, and that shields a
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`FIG. 2 is a cross-sectional view showing an example of
`magnetic field generated by the wireless high frequencysig-
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`using one piece of nanocrystalline ribbon sheet according to
`nal and simultaneously induces the secondary coil to absorb
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`a first embodimentof the present invention.
`the wireless high frequency signal necessary to perform a
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`FIG. 3 is a cross-sectional view showing an example of
`wireless charging function,
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`using six pieces of nanocrystalline ribbon sheets according to
`wherein the magnetic field shield sheet comprises:
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`a second embodimentof the present invention.
`at least one layer thin magnetic sheet made of an amor-
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`FIGS. 4 and5are cross-sectional views showingthestruc-
`phousribbon separated into a plurality of fine pieces;
`45
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`ture of a protective film and a double-sided tape that are
`a protective film that is adhered on onesurface of the thin
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`respectively used in the present invention.
`magnetic sheetvia a first adhesive layer provided on one side
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`FIG.6 is an exploded perspective view showing a magnetic
`of the protective film; and
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`field shield sheet for a wireless charger accordingto a third
`a double-sided tape that is adhered on the other surface of
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`embodimentof the present invention.
`the thin magnetic sheet via a second adhesive layer provided
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`FIG. 7 is a flowchart view for describing a process of
`on one side of the double-sided adhesive tape,
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`manufacturing a magnetic field shield sheet for a wireless
`wherein gaps amongtheplurality of fine pieces are filled by
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`charger accordingto the present invention.
`someparts ofthe first and second adhesivelayers, to thereby
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`FIGS. 8 and 9 are cross-sectional views showing a flake
`isolate the plurality of fine pieces.
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`treatmentprocess of a laminate sheet accordingto the present
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`Ad

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