Antenna, coil, and method for manufacturing coil
阅读说明:本技术 天线、线圈以及线圈的制造方法 (Antenna, coil, and method for manufacturing coil ) 是由 禹成宇 金辰旭 查理斯·L·布鲁佐恩 詹尼弗·J·索科尔 马修·R·C·阿特金森 于 2019-08-28 设计创作,主要内容包括:本发明描述了一种用于传送信息或能量的线圈。线圈包括导电磁绝缘第一层和沿第一层的长度粘结到第一层的导磁第二层。缠绕第一层和第二层以形成多个基本上同心的环。第二层的宽度和长度可以与第一层的相应宽度和长度基本上共同延伸,以便沿第一层的长度暴露第一层的相反的纵向边缘表面。相反的纵向边缘表面中的至少一个可以包括基本上沿相同的第一方向并跨基本上整个线圈延伸的规则图案。描述了一种制造线圈的方法。(The invention describes a coil for transmitting information or energy. The coil includes an electrically conductive, magnetically insulating first layer and a magnetically conductive second layer bonded to the first layer along a length of the first layer. The first layer and the second layer are wound to form a plurality of substantially concentric loops. The width and length of the second layer may be substantially coextensive with the respective width and length of the first layer so as to expose opposite longitudinal edge surfaces of the first layer along the length of the first layer. At least one of the opposing longitudinal edge surfaces may comprise a regular pattern extending in substantially the same first direction and across substantially the entire coil. A method of manufacturing a coil is described.)
1. An antenna for communicating information or energy, the antenna comprising:
an electrically conductive, magnetically insulating first layer having a width W, a thickness T, and extending longitudinally along a length L of the first layer between a first longitudinal end and a second longitudinal end of the first layer; and
a magnetically permeable second layer bonded to the first layer along a length of the first layer, the first and second layers being wound to form a plurality of substantially concentric rings, a width and length of the second layer being substantially coextensive with a corresponding width and length of the first layer so as to expose opposing longitudinal edge surfaces of the first layer along the length of the first layer.
2. The antenna defined in claim 1 wherein at least one of the opposing longitudinal edge surfaces of the first layer comprises a regular pattern that extends substantially transversely across an edge surface, the regular patterns of the edge surfaces of at least a plurality of adjacent rings of the substantially concentric plurality of rings being substantially aligned with one another.
3. The antenna defined in claim 2 wherein the fourier transform of the regular pattern has a peak at a first spatial frequency in a first region of the substantially concentric plurality of rings and a peak at a second, different spatial frequency in a second, different region of the substantially concentric plurality of rings.
4. A coil comprising a multilayer film wound to form a plurality of substantially concentric rings, the multilayer film comprising:
a magnetically conductive first layer; and
a plurality of alternating second and third layers disposed on and bonded to the first layer, the second layers being electrically conductive and magnetically insulating, the third layers being electrically and magnetically insulating, the first, second and third layers having widths and lengths substantially coextensive with one another such that longitudinal edge surfaces of the second layers are not covered by either the third or first layers.
5. A coil comprising a plurality of substantially concentric loops, each loop comprising an edge surface substantially perpendicular to an adjacent loop and comprising a regular pattern extending along a first direction, the first direction forming an angle with a longitudinal direction of the loop, the angle varying along the longitudinal direction of the loop.
6. A coil comprising a plurality of substantially concentric loops, each loop comprising an edge surface substantially perpendicular to an adjacent loop and comprising a regular pattern extending substantially transversely across the edge surface, the regular patterns of the edge surfaces of at least a plurality of adjacent loops being substantially aligned with each other.
7. A coil comprising a plurality of substantially concentric rings, each ring comprising a plurality of substantially concentric metal layers substantially concentric with at least one soft magnetic layer, such that in plan view the coil comprises a regular pattern of substantially parallel grooves extending across at least a plurality of adjacent rings of the plurality of substantially concentric rings.
8. A coil comprising a plurality of substantially concentric loops, each loop comprising a plurality of substantially concentric alternating metal layers and first adhesive layers, a second adhesive layer disposed between and bonding adjacent loops, the second adhesive layer being thicker than the first adhesive layer.
9. A coil comprising a plurality of substantially concentric loops, each loop comprising a metal layer, such that in plan view the coil comprises a regular pattern extending substantially along the same first direction and substantially across the entire coil, the regular pattern having a first average pitch in a first region of the coil and a different second average pitch in a different second region of the coil.
10. A coil comprising a plurality of substantially concentric loops, each loop comprising a metal layer, such that in plan view the coil comprises a regular pattern extending substantially along the same first direction and substantially across the entire coil, the fourier transform of the regular pattern having peaks at a first spatial frequency in a first region of the coil and having peaks at a second, different spatial frequency in a second region of the coil.
11. An antenna for transmitting information or energy, the antenna comprising a plurality of substantially concentric rings, each ring comprising a metal layer, such that in plan view and in at least one first area of the antenna, the antenna comprises a regular optical and topographical pattern along a first direction, and a regular optical but non-topographical pattern along an orthogonal second direction.
12. An antenna for communicating information or energy, the antenna comprising:
an electrically conductive, magnetically insulating first layer comprising opposing major surfaces and opposing edge surfaces connecting the opposing major surfaces; and
a magnetically permeable second layer disposed on and bonded to the first layer and substantially coextensive in length and width of the first layer so as not to cover an edge surface of the first layer, the first and second layers being wound to form a plurality of substantially concentric rings.
13. A substantially planar coil for conveying information or energy, the coil comprising:
an electrically conductive, magnetically insulating first layer; and
a magnetically permeable second layer disposed on and bonded to the first layer and substantially coextensive in length and width of the first layer so as not to cover an edge surface of the first layer.
14. A coil comprising a multilayer film wound to form a plurality of substantially concentric rings, the multilayer film comprising:
an electrically conductive, magnetically insulating first layer; and
a magnetically permeable second layer disposed on and bonded to the first layer such that corresponding edge surfaces of the first and second layers are substantially coplanar.
15. An assembly, the assembly comprising:
a rod; and
a multilayer film wound around a plurality of continuous turns substantially concentric with the stem, the multilayer film comprising:
a plurality of alternating metal layers and first adhesive layers; and
a magnetically permeable second layer disposed on and bonded to the alternating plurality of metal layers and first adhesive layers.
16. A method of manufacturing a coil, the method comprising:
providing an assembly comprising a rod and a film wound around a plurality of continuous turns substantially concentric with the rod, the film comprising an electrically conductive first layer; and
substantially transversely slicing through the assembly using at least one cutting wire to form separate portions of the assembly, the separate portions of the assembly comprising the coil comprising substantially concentric rings of the separate portions of the membrane.
Technical Field
The present invention relates to an antenna for transmitting information or energy, a coil, and a method of manufacturing the coil.
Background
The coils used in antennas are known. Inductive coupling between coils may be used for wireless power systems. In this method, a transmitter coil in one device transmits power across a short distance to a receiver coil in another device.
Disclosure of Invention
In some aspects of the present description, an antenna for transmitting information or energy is provided. The antenna includes an electrically conductive, magnetically insulative first layer having a width W, a thickness T and extending longitudinally along a length L of the first layer between a first longitudinal end and a second longitudinal end of the first layer, and a magnetically conductive second layer bonded to the first layer along the length of the first layer. The first layer and the second layer are wound to form a plurality of substantially concentric loops. The width and length of the second layer are substantially coextensive with the respective width and length of the first layer so as to expose opposite longitudinal edge surfaces of the first layer along the length of the first layer.
In some aspects of the present description, a coil is provided that includes a multilayer film wound to form a plurality of substantially concentric rings. The multilayer film includes a magnetically permeable first layer and a plurality of alternating second and third layers disposed on and bonded to the first layer. The second layer is electrically conductive and magnetically insulating. The third layer is electrically and magnetically insulating. The widths and lengths of the first, second and third layers are substantially coextensive with one another such that the longitudinal edge surfaces of the second layer are not covered by either the third layer or the first layer.
In some aspects of the present description, a coil is provided that includes a plurality of substantially concentric rings. Each ring includes an edge surface that is substantially perpendicular to an adjacent ring. The edge surface includes a regular pattern extending in a first direction forming an angle θ with the longitudinal direction of the ring. Theta varies along the longitudinal direction of the ring.
In some aspects of the present description, a coil is provided that includes a plurality of substantially concentric rings. Each ring includes an edge surface that is substantially perpendicular to an adjacent ring. The edge surface includes a regular pattern extending substantially laterally across the edge surface. At least the regular patterns of the edge surfaces of a plurality of adjacent rings are substantially aligned with each other.
In some aspects of the present description, a coil is provided that includes a plurality of substantially concentric rings. Each ring comprises a plurality of substantially concentric metal layers substantially concentric with the at least one soft magnetic layer such that, in plan view, the coil comprises a regular pattern of substantially parallel grooves extending across at least a plurality of adjacent rings of the plurality of substantially concentric rings.
In some aspects of the present description, a coil is provided that includes a plurality of substantially concentric rings. Each ring includes a plurality of substantially concentric alternating metal layers and first adhesive layers. A second adhesive layer is disposed between and bonded to adjacent rings. The second adhesive layer is thicker than the first adhesive layer.
In some aspects of the present description, a coil is provided that includes a plurality of substantially concentric rings. Each ring includes a metal layer. In plan view, the coil comprises a regular pattern extending substantially along the same first direction and across substantially the entire coil. The regular pattern has a first average pitch in a first region of the coil and a different second average pitch in a different second region of the coil.
In some aspects of the present description, a coil is provided that includes a plurality of substantially concentric rings. Each ring includes a metal layer. In plan view, the coil comprises a regular pattern extending substantially along the same first direction and across substantially the entire coil. The fourier transform of the regular pattern has a peak at a first spatial frequency in a first region of the coil and a peak at a second, different spatial frequency in a second, different region of the coil.
In some aspects of the present description, an antenna for transmitting information or energy is provided. The antenna comprises a plurality of substantially concentric rings, each ring comprising a metal layer, such that in plan view and in at least one first area of the antenna, the antenna comprises a regular optical and topographical pattern along a first direction, and a regular optical but non-topographical pattern along an orthogonal second direction.
In some aspects of the present description, an antenna for transmitting information or energy is provided. The antenna includes an electrically conductive, magnetically insulative first layer having opposed major surfaces and opposed edge surfaces connecting the opposed major surfaces, and a magnetically conductive second layer disposed on and bonded to the first layer and substantially coextensive in length and width of the first layer so as not to overlie the edge surfaces of the first layer. The first layer and the second layer are wound to form a plurality of substantially concentric loops.
In some aspects of the present description, a substantially planar coil for conveying information or energy is provided. The coil includes an electrically conductive, magnetically insulating first layer and a magnetically permeable second layer disposed on and bonded to the first layer and substantially coextensive in length and width of the first layer so as not to cover an edge surface of the first layer.
In some aspects of the present description, a coil is provided that includes a multilayer film wound to form a plurality of substantially concentric rings. The multilayer film includes an electrically conductive, magnetically insulating first layer, and a magnetically permeable second layer disposed on and bonded to the first layer such that respective edge surfaces of the first and second layers are substantially coplanar.
In some aspects of the present description, a coil or antenna is provided that includes a plurality of loops. Each ring includes at least one conductive layer and at least one other layer. Each ring may include a plurality of conductive layers, which may alternate with a plurality of adhesive layers. The at least one other layer may comprise one or more magnetically permeable and/or soft magnetic layers. In some aspects of the present description, a method of manufacturing a coil or antenna is provided. The method includes cutting or slicing through the assembly to provide separate portions of the assembly, the separate portions of the assembly including the coil or antenna.
In some aspects of the present description, an assembly is provided that includes a stem and a multilayer film wound around a plurality of continuous turns substantially concentric with the stem. The multilayer film includes a plurality of alternating metal layers and first adhesive layers, and a magnetically permeable second layer disposed on and bonded to the plurality of alternating metal layers and first adhesive layers.
In some aspects of the present description, a method of manufacturing a coil is provided. The method includes providing a rod; providing a multilayer film comprising an electrically conductive first layer and a magnetically permeable second layer disposed on the first layer; winding the multilayer film around a rod to form an assembly comprising the rod and a plurality of rings of the multilayer film substantially concentric with the rod; and cutting substantially transversely through the assembly to form separate portions of the assembly. The separate part of the assembly comprises a coil. The coil comprises a plurality of substantially concentric rings of separate portions of the multilayer film.
In some aspects of the present description, a method of manufacturing a coil is provided. The method includes providing a rod; providing a multilayer film comprising a plurality of alternating electrically conductive layers and first adhesive layers, and comprising a second adhesive layer comprising an outermost major surface of the multilayer film; wrapping the multilayer film around the stem to form an assembly comprising the stem and a plurality of rings of the multilayer film substantially concentric with the stem, wherein each ring is bonded to an adjacent ring by a second adhesive layer; and cutting substantially transversely through the assembly to form separate portions of the assembly. The separate part of the assembly comprises a coil. The coil comprises a plurality of substantially concentric rings of separate portions of the multilayer film.
In some aspects of the present description, a method of manufacturing a plurality of coils is provided. The method includes providing a rod; providing a multilayer film comprising a conductive first layer and a second layer disposed on and bonded to the first layer; winding the multilayer film around a rod to form an assembly comprising the rod and a plurality of rings of the multilayer film substantially concentric with the rod; and cutting a substantially transverse slice through the assembly using a plurality of spaced apart cut lines to form a plurality of separate portions of the assembly, wherein each separate portion of the assembly comprises a loop of the plurality of loops, and each loop comprises a substantially concentric plurality of loops of the separate portion of the multilayer film.
In some aspects of the present description, a method of manufacturing a coil is provided. The method includes providing an assembly including a rod and a film wound around a plurality of continuous turns substantially concentric with the rod, the film including an electrically conductive first layer; and cutting a substantially transverse slice through the assembly using at least one cutting wire to form a separated portion of the assembly, the separated portion of the assembly comprising a coil, wherein the coil comprises a substantially concentric plurality of loops of the membrane separated portion.
Drawings
Fig. 1A to 1B are schematic top plan and side views, respectively, of a coil;
FIG. 1C is a schematic cross-sectional view of a multilayer film of the coil of FIGS. 1A-1B;
FIG. 1D is a schematic top view of an assembly including the coils of FIGS. 1A-1B;
FIG. 2 is a schematic top plan view of a coil;
fig. 3A to 3B are schematic top plan views of the coil;
fig. 3C is a schematic bottom plan view of the coil of fig. 3A-3B;
FIG. 4 is a schematic end view of a multilayer film;
fig. 5A to 5B are schematic end and side views, respectively, of a multilayer film;
FIG. 6 is a top view of an assembly including an antenna;
FIG. 7A is a laser intensity image of a portion of a coil;
FIG. 7B is a schematic top plan view of a portion of a coil;
FIGS. 8A-8B are laser intensity images and topographical maps, respectively, of a first region of a coil;
FIG. 9 is a topographical view of a portion of the first region of the coil of FIGS. 8A-8B;
FIG. 10 is a graph of topography in a first region of the coil of FIGS. 8A-8B along a first direction;
FIG. 11 is a graph of topography in a first region of the coil of FIGS. 8A-8B in a second orthogonal direction;
FIG. 12 is a graph of the magnitude of the two-dimensional Fourier transform of the surface topography in the first region of the coil of FIGS. 8A-8B;
FIG. 13 is a graph of Fourier transform magnitude of surface topography in a first direction in a first region of the coil of FIG. 12;
FIG. 14 is a graph of the magnitude Fourier transform of the surface topography in a second direction in a first region of the coil of FIG. 12;
FIGS. 15A-15B are laser intensity images and topographical maps of a second region of the coil of FIGS. 8A-8B, respectively;
FIG. 16 is a topographical view of a portion of the second region of the coil of FIGS. 15A-15B;
FIG. 17 is a graph of topography in a first direction in a second region of the coil of FIGS. 15A-15B;
FIG. 18 is a graph of topography in a second direction in a second region of the coil of FIGS. 15A-15B;
FIG. 19 is a graph of the magnitude of the Fourier transform of the surface topography in the second region of the coil of FIGS. 15A-15B;
FIG. 20 is a graph of the magnitude Fourier transform of the surface topography in the first direction in the second region of the coil of FIGS. 15A-15B;
fig. 21 is a graph of the magnitude fourier transform of the surface topography in the second direction in the second region of the coil of fig. 15A-15B.
FIGS. 22A-22B are laser intensity images and topographical maps of a third region of the coil of FIGS. 8A-8B, respectively;
FIG. 23 is a graph of topography in a second direction in a third region of the coil of FIGS. 22A-22B;
FIG. 24 is a graph of the magnitude of the Fourier transform of the surface topography in the third region of the coil of FIGS. 22A-22B;
FIG. 25 is a graph of Fourier transform magnitude of surface topography along a first direction in a third region of the coil of FIGS. 22A-22B;
FIG. 26 is a graph of Fourier transform magnitude of surface topography in a second direction in a third region of the coil of FIGS. 22A-22B;
FIGS. 27A-27B are laser intensity images and topographical maps of a fourth region of the coil of FIGS. 8A-8B, respectively;
FIG. 28 is a graph of topography in a second direction in a fourth region of the coil of FIGS. 27A-27B;
FIG. 29 is a graph of the magnitude of the Fourier transform of the surface topography in the fourth region of the coil of FIGS. 27A-27B;
FIG. 30 is a graph of the Fourier transform of the surface topography in the first direction in the fourth region of the coil of FIGS. 27A-27B;
FIG. 31 is a graph of Fourier transform magnitude of surface topography in a second direction in a fourth region of the coil of FIGS. 27A-27B;
FIG. 32 is a top view of the coil;
FIGS. 33A-33B are laser intensity images and topographical maps, respectively, of a contrast coil in the first region;
FIG. 34 is a topographical view of a portion of the first region of the coil of FIGS. 33A-33B;
FIGS. 35A-35B are graphs of topography at a smaller and larger scale of coordinate length along a first direction in a first region of the coil of FIGS. 33A-33B, respectively;
fig. 36 is a graph in the first region of the coil of fig. 33A-33B along the second direction in the first region;
FIG. 37 is a graph of Fourier transform magnitude of surface features in a first region of the coil of FIGS. 33A-33B;
FIG. 38 is a graph of Fourier transform magnitude of surface topography in a first direction in a first region of the coil of FIGS. 33A-33B;
FIG. 39 is a graph of Fourier transform magnitude of surface topography in a second direction in a first region of the coil of FIGS. 33A-33B;
40A-40B are laser intensity images and topographical maps of the contrast coil in the second region of FIGS. 33A-33B, respectively;
FIG. 41 is a topographical view of a portion of the second region of the coil of FIGS. 40A-40B;
FIG. 42 is a graph of topography in a first direction in a second region of the coil of FIGS. 40A-40B;
FIGS. 43A-43B are graphs of topography at a second direction on a scale of smaller and larger coordinate lengths in a second region of the coil of FIGS. 40A-40B, respectively;
FIG. 44 is a graph of the magnitude of the Fourier transform of the surface topography in the second region of the coil of FIGS. 40A-40B;
FIG. 45 is a graph of a Fourier transform of the surface topography in the first direction in the second region of the coil of FIGS. 40A-40B;
FIG. 46 is a graph of a Fourier transform of the surface topography in a second direction in a second region of the coil of FIGS. 40A-40B;
FIG. 47 is a top view of a coil;
FIGS. 48A-48B are laser intensity images and topographical maps, respectively, of a comparison coil in a first region of the coil;
FIG. 48C is a topographical view of a portion of the first region of the coil of FIGS. 48A-48B;
FIGS. 49A-49B are topographical maps at a smaller and larger coordinate length scale in a first direction in a first region of the coil of FIGS. 48A-48B, respectively;
FIG. 50 is a graph of topography in a second direction in a first region of the coil of FIGS. 48A-48B;
FIG. 51 is a graph of Fourier transform magnitude of surface features in a first region of the coil of FIGS. 48A-48B;
FIG. 52 is a graph of Fourier transform magnitude of surface topography in a first direction in a first region of the coil of FIGS. 48A-48B;
FIG. 53 is a graph of a Fourier transform of the surface topography in the second direction in the first region of the coil of FIGS. 48A-48B;
FIGS. 54A-54B are laser intensity images and topographical maps of a second region of the coil of FIGS. 48A-48B, respectively;
FIG. 55 is a topographical view of a portion of the second region of the coil of FIGS. 54A-54B;
FIG. 56 is a graph of topography in a first direction in a second region of the coil of FIGS. 54A-54B;
FIGS. 57A-57B are graphs of topography at a second direction on a scale of smaller and larger coordinate lengths in a second region of the coil of FIGS. 54A-54B, respectively;
FIG. 58 is a graph of Fourier transform magnitude of surface features in a second region of the coil of FIGS. 54A-54B;
FIG. 59 is a graph of a Fourier transform of the surface topography in the second region of the coil of FIGS. 54A-54B along the first direction;
FIG. 60 is a graph of a Fourier transform of the surface topography in a second direction in a second region of the coil of FIGS. 54A-54B;
FIG. 61 is a schematic view of a multilayer film with one end inserted into a slit in a stem;
fig. 62 is a schematic of a multilayer film wrapped around a rod.
FIG. 63 is a schematic perspective view of the assembly;
FIG. 64 is a schematic illustration of slicing the assembly to produce one or more coils;
FIG. 65 is a schematic side perspective view of a diamond wire; and is
Fig. 66 is a schematic side view of a transceiver.
Detailed Description
In the following description, reference is made to the accompanying drawings, which form a part hereof and in which is shown by way of illustration various embodiments. The figures are not necessarily to scale. It is to be understood that other embodiments are contemplated and may be made without departing from the scope or spirit of the present description. The following detailed description is, therefore, not to be taken in a limiting sense.
The coils described herein may be used to transmit information (e.g., digital or analog data) or energy (e.g., energy for wireless charging). It has been found that coils comprising one or more magnetically permeable and/or soft magnetic layers and one or more electrically conductive layers are useful in applications where efficient transfer of information or energy is required. For example, the coil may be used for wireless charging of a battery that powers an electronic device (such as a cellular telephone). The coil may be used to direct a magnetic field during wireless charging, to shield a battery and/or other electronic device components from electromagnetic fields, to reduce eddy currents caused by the magnetic field, and/or to, for example, enhance the transfer efficiency and/or Q-factor of the wireless charging system. For example, the term antenna may be used to refer to a coil configured to transmit information or energy.
When higher and lower permeability materials are used together (e.g., in a coil), the magnetic field lines tend to be more concentrated in the higher permeability material and less concentrated in the low permeability material, so the high permeability (e.g., significantly higher than vacuum permeability) material may be described as magnetically permeable, and the low permeability (e.g., comparable to vacuum permeability) material may be described as magnetically insulating.
The magnetically permeable material or layer is a material or layer having a relative permeability of at least 2, and the magnetically insulating material or layer is a material or layer having a relative permeability of no more than 1.5. In some embodiments, the relative permeability of the magnetically permeable layer is greater than 2, or greater than 10, or greater than 100. In some embodiments, the magnetic insulating layer has a relative permeability of less than 1.5, or less than 1.4, or less than 1.2, or less than 1.1, or less than 1.05. In some embodiments, the relative permeability of the magnetic-insulating layer is, for example, in the range of 0.99 to 1.05. In some embodiments, the coil comprises a plurality of loops, wherein each loop comprises a magnetically insulating layer and a magnetically permeable layer. In some embodiments, the relative permeability of the magnetically permeable layer is at least 10 times, or at least 100 times, the relative permeability of the magnetically insulating layer. Unless otherwise stated, relative permeability refers to the real part of the complex relative permeability.
A substantially non-magnetic metal is a metal that has a relative permeability near 1 (e.g., in the range of 0.98 to 1.1, or 0.99 to 1.05, or 0.99 to 1.01) and does not have a stable magnetically ordered phase. The stable phase is a macroscopic phase that is thermodynamically stable at 20 ℃ in the absence of an applied magnetic field, unless otherwise indicated. The magnetically ordered phases include a ferromagnetic phase, an antiferromagnetic phase, and a ferrimagnetic phase.
The soft magnetic material or layer is a material or layer having a coercivity no greater than 1000A/m. Coercivity is a measure of the magnetic field strength required to demagnetize a material. A soft magnetic material or magnetic material with a low coercivity can be described as a magnetic material that is prone to demagnetization. In some embodiments, the coercivity of the soft magnetic layer is less than 1000A/m, or less than 100A/m, or less than 50A/m, or less than 20A/m.
In some embodiments, the magnetically permeable layer is soft magnetic. The relative permeability of such layers may be greater than 2, or greater than 10, or greater than 100; and a coercivity of less than 1000A/m, or less than 100A/m, or less than 50A/m, or less than 20A/m.
The magnetically permeable or soft magnetic layer may be electrically conductive (e.g., resistivity no greater than 200 μ Ω cm) or electrically insulating (e.g., resistivity at least 100 Ω m). In some embodiments, the electrically insulating layer (e.g., a magnetically permeable electrically insulating layer or an electrically insulating soft magnetic layer) has a resistivity of greater than 100 Ω m, or greater than 200 Ω m, or greater than 500 Ω m, or greater than 1000 Ω m. In some embodiments, the electrically conductive layer (e.g., a magnetically insulating electrically conductive layer, or a magnetically permeable electrically conductive layer, or an electrically conductive soft magnetic layer) has a resistivity of less than 200 μ Ω cm, or less than 100 μ Ω cm, or less than 50 μ Ω cm, or less than 20 μ Ω cm, or less than 10 μ Ω cm. In some embodiments, the magnetically permeable and/or soft magnetic material is electrically conductive. The conductive layer may be formed as a continuous layer of such magnetic material. The electrically insulating layer may be formed by dispersing particles of such magnetic material in an electrically insulating binder in a concentration such that no electrically continuous path is formed through the layer. At higher concentrations, the layer may become conductive. In some embodiments, the composite layer includes different types of soft magnetic particles, some of which are electrically conductive and others of which are electrically insulating. The resistivity can be adjusted by adjusting the volume fraction of the conductive particles. Unless otherwise specified, resistivity refers to intrinsic resistivity.
Unless otherwise specified, magnetic and electrical properties (e.g., relative permeability, coercivity, resistivity) refer to the corresponding properties evaluated at low frequencies (e.g., about 1kHz or less) or statically (direct current), and measured at 20 ℃.
Any suitable magnetic material may be used for the magnetically permeable and/or soft magnetic layers. Crystalline alloys comprising any two or all three of iron, cobalt or nickel may be used. Additional elements may optionally be added to alter properties such as magnetostriction, resistivity, permeability, saturation induction, coercivity, remanence, and/or corrosion. Examples of such alloys include NiFe, NiFeMo, FeSi, FeAlSi, and FeCo. Amorphous alloys may also be used. For example, amorphous alloys comprising cobalt and/or iron, and metalloids such as silicon and boron may be used. Such alloys are known in the art. Nanocrystalline materials, such as nanocrystalline alloys, may also be used. For example, nanocrystalline alloys comprising iron, silicon and/or boron may be used, as well as optional other elements added during annealing to control nucleation and growth of the nanocrystals. Many of these alloys include iron, silicon, boron, niobium, and copper. Useful FeSiBNbCu alloys include those available under the trade name VITROPERM from wackera (Vacuumschmelze) and FINEMET from Hitachi Metals Ltd. Ferrite may also be used. The ferrite includes an oxide of iron and at least one other metal. Examples of useful ferrites include soft cubic ferrite materials such as MnZn-ferrite or NiZn-ferrite. Such materials are available from a number of suppliers such as Ferroxcube.
In some embodiments, the magnetically permeable and/or soft magnetic layer comprises a metal, such as, for example, an alloy. In some embodiments, the alloy is a ferrous alloy. In some embodiments, the alloy comprises iron, and at least one of silicon, aluminum, boron, niobium, copper, cobalt, nickel, or molybdenum. In some embodiments, the alloy comprises iron, and at least one of silicon, boron, niobium, or copper. In some embodiments, the alloy comprises iron, silicon, and boron, and in some embodiments, the alloy further comprises niobium and copper. In some embodiments, the alloy comprises iron, and at least one of silicon and aluminum. In some embodiments, the alloy comprises iron, aluminum, and silicon. In some embodiments, the alloy comprises nickel and iron. In some embodiments, the alloy comprises iron, cobalt, and nickel. In some embodiments, the alloy comprises nickel, iron, and molybdenum. In some embodiments, the alloy comprises iron and silicon. In some embodiments, the alloy comprises nickel, iron, and molybdenum. In some embodiments, the alloy is a crystalline alloy. In some embodiments, the crystalline alloy comprises at least two different metals selected from the group consisting of iron, cobalt, and nickel. In some embodiments, the alloy is a nanocrystalline alloy. In some embodiments, the nanocrystalline alloy comprises iron, silicon, boron, niobium, and copper. In some embodiments, the alloy is an amorphous alloy. In some embodiments, the amorphous alloy comprises at least one of cobalt or iron, and at least one of silicon or boron. In some embodiments, the magnetically permeable and/or soft magnetic layer comprises a ferrite, such as manganese-zinc ferrite or nickel-zinc ferrite.
In some embodiments, a continuous electrically conductive layer of a ferrous alloy is used as the magnetically permeable and/or soft magnetic layer. In some embodiments, the magnetically permeable layer or the soft magnetic layer comprises particles (e.g., magnetically permeable filler) dispersed in a binder (e.g., at least one of a thermosetting adhesive, an epoxy, or a mixture including an epoxy). The magnetically permeable filler may be or comprise particles of any of the above mentioned magnetic materials. In some embodiments, the particles are metal particles that may be or include, for example, an iron-silicon-boron-niobium-copper alloy, or may be or include, for example, an iron-aluminum-silicon alloy (e.g., an iron-silicon-aluminum alloy). In some embodiments, the particles are ferrite particles, such as manganese-zinc ferrite particles or nickel-zinc ferrite particles. Other suitable materials for the particles or for the continuous magnetically permeable and/or soft magnetic layer include permalloy, molybdenum permalloy, and superalloys. Combinations of different particles may also be used. In some embodiments, the particles comprise metal particles comprising at least one of an iron-silicon-boron-niobium-copper alloy or an iron-aluminum-silicon alloy. The particles can have any suitable shape and size. In some embodiments, the particles are flakes. The sheet may have a smaller thickness (e.g., at least 4 times, or at least 8 times smaller) than the maximum transverse dimension of the sheet, and may have an irregular edge shape, for example.
Useful electrically conductive, magnetically insulating materials include substantially non-magnetic metals such as, for example, non-ferrous metals and austenitic stainless steels. A non-ferrous metal is a metal, which may be an elemental metal or metal alloy, that does not contain appreciable amounts of iron (e.g., no iron, or only small amounts (e.g., trace amounts) of iron, which does not substantially affect the magnetic properties of the metal). Useful non-ferrous metals include, for example, aluminum, copper, zinc, lead, silver, and alloys thereof. In some embodiments, the electrically conductive, magnetically insulating layer for the antenna or coil is or includes a metal, which may be or include, for example, copper or a copper alloy.
In some aspects of the present description, methods are described for efficiently manufacturing one or more coils or antennas. In some embodiments, a method of manufacturing a coil or antenna includes the step of winding a film having at least one conductive layer around a rod to form an assembly as further described elsewhere herein. For example, the film may include one or more metal layers. The use of multiple thinner metal layers allows the film to be wound around the rod to form a ring or loop that is substantially concentric with the rod, which is easier to implement than a single metal layer having the same overall thickness (e.g., to provide substantially the same low frequency resistance along the length). In some cases, it is advantageous to use multiple thinner layers to provide increased surface area, which reduces the accumulation of the effective resistance of the coil due to the reduction in skin depth at higher frequencies. In some embodiments, a method of manufacturing a coil or antenna includes slicing one or more diamond wires through an assembly to form a segment of the assembly that includes the coil or antenna. The slicing or other method may produce a regular pattern (e.g., a regular pattern of substantially parallel grooves) on one or both sides of the coil or antenna. Such regular patterns are further described elsewhere herein.
Substantially concentric objects (e.g., substantially concentric rings in a coil) have the same or close centers (e.g., centered within 20%, or within 10%, or within 5% of the maximum lateral dimension (e.g., the diameter of the outermost ring)). For example, the substantially concentric rings may have a substantially circular, elliptical, or rounded rectangular shape.
The multilayer film may include adjacent layers bonded to each other by an adhesive layer, and adjacent loops of the coil or antenna may be bonded to each other by an adhesive layer. Useful adhesives may be, for example, one or more of a thermosetting adhesive, an epoxy, an acrylate, or a polyurethane.
Fig. 1A-1B are schematic top and side views of a
If a first length or width of a first layer is substantially coextensive with a first length or width of a second layer, the respective lengths or widths substantially overlap each other (e.g., the first length or width overlaps at least 80%, or at least 90%, or at least 95% of the second length or width; and the first length or width overlaps at least 80%, or at least 90%, or at least 95% of the first length or width).
In some embodiments, the antenna or
In some embodiments, the
In some cases, for example, the
The thickness and width of each layer may be selected to be any suitable value. In some embodiments, a thinner
In some embodiments, the antenna or
In some embodiments,
The antenna or
Fig. 1C is a schematic cross-sectional view of the
Fig. 1D is a schematic top view of an
The
In some embodiments, a coil or
In some embodiments, the
In some embodiments, a substantially
In some embodiments of the antenna or
The
Fig. 3A-3B are schematic top views of an antenna or
In some embodiments, each
The second regular pattern 120b may have any of the attributes described further elsewhere herein with respect to the
In some embodiments, substantially concentric rings refer to rings of a multilayer film, for example. Each
In some embodiments, each
In some embodiments, the
In some embodiments, the at least one soft magnetic layer of each ring is disposed between the plurality of substantially concentric metal layers of the ring and the plurality of substantially concentric metal layers of an adjacent ring. In some embodiments, the first
In some embodiments, the plurality of substantially concentric metal layers in each ring are electrically connected to each other. For example, the metal layers in each ring may be soldered together at one or both ends of the ring, or may be electrically connected to each other at one or both ends of the ring, for example when the coil is connected to a cable by soldering. The
In some embodiments, the antenna or
In some embodiments, the fourier transform of the regular pattern has a peak at a first spatial frequency in a
Also shown in fig. 3B are third and
In some embodiments, a coil or antenna (e.g., 100, 200, or 300) of the present description may be described as comprising a multilayer film wound to form a plurality of substantially concentric loops (e.g., loop 110).
Fig. 4 is a schematic end view of an embodiment of a
In some embodiments, the
In some embodiments, the multilayer film includes an additional
In some embodiments, the coil comprises a multilayer film (e.g., 202 or 402 or 502) wound to form a plurality of substantially concentric rings (e.g., ring 110). In some embodiments, the multilayer film includes a plurality of alternating electrically
The membrane may have two dimensions that are much larger than the third dimension. A strip of film may be cut from the film such that the strip has one dimension that is much larger than the other two dimensions. The multilayer film used for the coil or antenna of the present description may be a film strip or a portion of a film strip.
Fig. 6 is a top view of
In some embodiments, the coil comprises a plurality of substantially concentric rings, wherein each ring is a ring of a multilayer film (e.g.,
The second
In some embodiments, the second
In some embodiments, the antenna or coil comprises a plurality of substantially
In some embodiments, the antenna or coil comprises a multilayer film wound to form a plurality of substantially concentric loops, wherein the multilayer film comprises a magnetically permeable
Fig. 8A-8B are laser intensity images and topography maps of a coil or
FIG. 9 is a topographical view of a portion of a first region obtained using a Keyence VK-X200 confocal microscope. Fig. 10 is a graph of topography (height of the surface relative to a reference plane) in the x-direction, and fig. 11 is a graph of topography (height) in the y-direction in the first region. The graphs in fig. 10 to 11 were extracted from the topographic map using a Keyence VK-X200 confocal microscope. As can be seen in fig. 8A to 9, the optical pattern exists in both the x-direction and the y-direction. As can be seen in fig. 10, there is substantially no topographical pattern across the multiple metal layers along the y-direction. As can be seen in fig. 11, there is a base topographic pattern across the multiple metal layers along the y-direction. The topographical pattern in the first region had an average pitch P1 in the y-direction of about 89 microns (determined by approximating the average pitch as the inverse of the corresponding fourier transform peak frequency). In some embodiments, the antenna or coil includes a regular optical and
In some embodiments, the regular optical and
FIG. 12 is a graph of the magnitude of a two-dimensional Fourier transform of the surface topography in the first region. Fig. 13 is a graph of fourier transform magnitude in the x-direction, and fig. 14 is a graph of magnitude fourier transform in the y-direction in the first region. The fourier transform in the y-direction has a peak K1 at spatial frequency F1. The peak K1 indicates the periodic pattern shown in fig. 11. The peak K1 is substantially spaced apart from any adjacent peak. The fourier transform along the x-direction shown in fig. 13 does not have a peak at non-zero spatial frequencies that are substantially spaced apart from any adjacent peak. This indicates the lack of a topographical pattern along the x-direction.
Fig. 15A-15B are laser intensity images and topographical maps of the coil or
FIG. 19 is a graph of Fourier transform magnitude of surface features in the second region. Fig. 20 is a graph of the magnitude fourier transform in the x direction, and fig. 21 is a graph of the magnitude fourier transform in the y direction in the second region. The fourier transform in the y-direction has a peak K2 at spatial frequency F2. The peak K2 indicates the periodic pattern shown in fig. 18. The peak K2 is substantially spaced apart from any adjacent peak having a similar magnitude. The fourier transform along the x-direction shown in fig. 20 does not have any such peaks; this indicates that there is substantially no topographical pattern along the x-direction.
Fig. 22A-22B are laser intensity images and topographical maps of the coil or
Fig. 27A-27B are laser intensity images and topographical maps of the coil or
Fig. 32 is a top plan view of a
Fig. 33A-33B are laser intensity images and topographical maps of the
Fig. 40A-40B are laser intensity images and topographical maps, respectively, of a
Fig. 33A to 46 show that the topographic pattern of the
Fig. 47 is a top plan view of the
Fig. 48A-48B are laser intensity images and topographical maps of the
Fig. 54A-54B are laser intensity images and topography images, respectively, of the
Fig. 48A to 60 show that the topographic pattern of the
In some embodiments, a method of making a coil or antenna includes providing a rod, providing a film (e.g., a multilayer film comprising at least one conductive layer, or any of the multilayer films described elsewhere herein), winding the film around the rod to form an assembly (e.g., comprising a plurality of continuous turns of the film substantially concentric with the rod, or substantially concentric rings), and cutting substantially transversely through the assembly to form the coil or antenna. For example, a section of the assembly may be cut from the assembly and include a coil or antenna wound around a section of the rod, which may optionally be removed. The cutting step may produce any of the regular patterns described elsewhere herein on one or both of the opposite sides of the coil or antenna (e.g., by slicing the assembly with parallel spaced apart diamond wires).
The shaft can extend along an axis and have a cross-section orthogonal to the axis that has any suitable shape (e.g., circular, elliptical, or rounded rectangular (e.g., a rounded rectangular shape corresponding to an interior region of the coil 3300)). The rod may be constructed of any suitable material. Suitable materials may include at least one of rigid polymers, cross-linked polymers, and epoxies. For example, the rod may include epoxy (e.g., the rod may be an epoxy rod).
Fig. 61 to 64 schematically show a method for manufacturing the coil or antenna of the present specification.
A
In some embodiments, the
In some embodiments, the method further comprises cutting the
In some embodiments, a method of manufacturing a coil includes providing a
In some embodiments, the
In some embodiments,
In some embodiments, the
In some embodiments, prior to winding the multilayer film, the multilayer film includes an uncured or partially cured first adhesive layer (e.g., 30 or 40 or 41 or 42) bonding the second layer to the first layer. In some embodiments, prior to winding the multilayer film, the multilayer film includes an uncured or partially cured second adhesive layer (e.g., 41 or 42) that includes the outermost
In some embodiments, the cutting or dicing step produces an
The
In some embodiments, a method includes the step of providing an
In some embodiments, wire saw 6494 is used to cut or slice through
In some embodiments, the cutting line for slicing through the assembly is a diamond wire. Diamond cutting wires may comprise wires impregnated with diamond powder and have been used, for example, to slice ceramics. Fig. 65 is a schematic view of a
The coils or antennas of the present description may be used to transmit information (e.g., digital or analog data) or energy (e.g., for wireless recharging). Figure 66 is a schematic side view of a
If the use of "about" in the context of the amounts used and described in this specification is unclear to those of ordinary skill in the art as applied to expressing feature sizes, amounts, and physical properties, then "about" will be understood to mean within 10% of the specified amount, but also including the exact specified amount. For example, if it is not clear to a person of ordinary skill in the art in the context of the use and description in this specification, an amount having a value of about 1 means that the amount has a value between 0.9 and 1.1, and also includes a value that is exactly 1.
All cited references, patents, or patent applications cited above are hereby incorporated by reference in their entirety in a consistent manner. In the event of inconsistencies or contradictions between the incorporated reference parts and the present application, the information in the preceding description shall prevail.
Unless otherwise indicated, descriptions with respect to elements in the figures should be understood to apply equally to corresponding elements in other figures. Although specific embodiments have been illustrated and described herein, it will be appreciated by those of ordinary skill in the art that a variety of alternate and/or equivalent implementations may be substituted for the specific embodiments shown and described without departing from the scope of the present disclosure. This application is intended to cover any adaptations or variations of the specific embodiments discussed herein. Accordingly, the disclosure is intended to be limited only by the claims and the equivalents thereof.
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