Installation method of energy transmission coil

Abstract

The invention discloses a mounting method of an energy transfer coil, which comprises the following steps of: performing leaking stoppage treatment on a structural member, putting the energy transfer coil into the structural member after the leaking stoppage treatment is completed, performing potting on the position, where the energy transfer coil is placed, on the structural member after glue mixing treatment is performed to prepare a potting material to form a potting layer, and performing curing treatment on the structural member after the potting is completed. And finally, completing the installation after the detection is qualified. Through the structural design of the structural member and the energy transfer coil and the potting process, the problem of eddy current generated by the metal structural member to the energy transfer coil is effectively solved, and the energy transfer efficiency is improved. The use of the encapsulating material enhances the fixity and leakproofness of the coil, and improves the durability and waterproofness of the energy transfer coil. The arrangement of the encapsulation layer avoids the problem that the energy transfer coil is easy to damage in a traditional fixing mode, and prolongs the service life of the energy transfer coil. The potting process is simple and easy to implement, high in operability and suitable for large-scale production and application.

Description

Technical Field

[0001] The present invention belongs to the technical field of wireless energy transmission, and particularly relates to a method for installing an energy transmission coil. Background Art

[0002] In the existing methods for installing an energy transmission coil, screws, clips, magnets, brackets or supports, and glue or adhesives are often used to fix the energy transmission coil on a structural member. However, these fixing methods often have the problem of being unreliable, and the ferrite in the energy transmission coil is easily broken when subjected to external force impact. In addition, when the energy transmission coil is installed in a metal structural member, the metal structural member is likely to generate eddy currents in the coil, resulting in a reduction in energy transmission efficiency.

[0003] The patent document with the publication number CN104700981A discloses a surface-mounted inductor and a manufacturing method thereof, which reduces the electrical contact resistance value between an external electrode and a metal core of an insulating coil.

[0004] The patent document with the publication number CN117335616A discloses a method for potting a voice coil motor coil. By taking advantage of the performance of epoxy resin, the coil is integrally potted with a heat sink with little change in the volume and mass of the voice coil motor to complete the shaping of the coil, so as to improve the rigidity, insulation performance, and high thermal conductivity of the coil.

[0005] However, the above patent documents do not solve the technical problem of eddy currents generated by the metal structural member in the coil. Summary of the Invention

[0006] The present invention provides a method for installing an energy transmission coil, which can solve the problems of unreliable fixing method, easy damage of the energy transmission coil, and reduction of energy transmission efficiency caused by eddy currents generated by the metal structural member in the energy transmission coil.

[0007] The present invention is achieved through the following technical solutions.

[0008] A method for installing an energy transmission coil provided by the present invention includes the following steps:

[0009] S1: Perform leak stoppage treatment on the structural member. After completion, place the energy transmission coil into the structural member.

[0010] S2: After preparing the potting material through glue mixing treatment, pot the place on the structural member where the energy transmission coil is placed to form a potting layer.

[0011] S3: After potting is completed, perform curing treatment on the structural member, and finally complete the installation after passing the inspection.

[0012] Preferably, the energy transfer coil includes a coil body and a fixing body. The coil body is connected to the fixing body, and there is a gap between the outer edge of the coil body and the outer edge of the fixing body. The energy transfer coil does not contact the structural member.

[0013] Preferably, the coil body is an exciting wire, and the fixing body is a ferrite.

[0014] Preferably, a placement groove is provided on the structural member. After the energy transfer coil is placed in the placement groove, potting is performed to form a potting layer.

[0015] Preferably, the leak stoppage treatment in step S1 includes the process of using tape and silicone rubber to stop the leak of the through holes on the structural member.

[0016] Preferably, the potting material in step S2 is BEEP 6225 thermosetting potting adhesive, and the available time after preparing the BEEP 6225 silicone rubber by mixing the glue is 120 min.

[0017] Preferably, in step S2, potting is first performed at the bottom of the placement groove to obtain an initial potting layer. During the time when the potting material is not cured, the energy transfer coil is placed flat with the wire flat at the center of the initial potting layer, and then potting is continued until the potting material covers the energy transfer coil. The top of the potting layer formed after potting is flush with the surface of the structural member.

[0018] Preferably, the curing treatment includes two curing processes. The first curing is performed after potting, and the first curing is to maintain at 80 ± 10 °C for 2 - 3 h. The second curing is to maintain at 100 ± 10 °C for 2 - 3 h.

[0019] Preferably, the first curing needs to be performed within 2 h after potting, and different curing devices are required for the two curing processes respectively.

[0020] Preferably, the detection step includes using a brush to dip anhydrous ethanol and brush back and forth 5 - 10 times at the same position on the surface of the potting layer. If there is no delamination, peeling, or flowing phenomenon on the potting layer, it is qualified.

[0021] The beneficial effects of the present invention are as follows:

[0022] Through the structural design of the structural member and the energy transfer coil and the potting process, the present invention effectively solves the eddy current problem generated by the metal structural member on the energy transfer coil and improves the energy transfer efficiency. The use of the potting material enhances the fixing and sealing properties of the coil, improving the durability and waterproofness of the energy transfer coil. The setting of the potting layer avoids the problem that the energy transfer coil is easily damaged in the traditional fixing method and extends the service life of the energy transfer coil. The potting process of the present invention is simple and easy to implement, with strong operability, and is suitable for large-scale production and application. Description of the Drawings

[0023] Figure 1 It is a schematic structural diagram of the energy transfer coil of the present invention;

[0024] Figure 2 It is a schematic structural diagram of the potting of the energy transfer coil of the present invention;

[0025] Figure 3 It is a process flow chart of the present invention;

[0026] In the figure: 1 - structural member, 2 - energy transfer coil, 3 - potting layer, 4 - coil body, 5 - fixing body, 6 - placement groove. Specific embodiments

[0027] The technical solution of the present invention will be further described below, but the scope of protection is not limited thereto.

[0028] Example 1:

[0029] As Figures 1 to 3 shown, an installation method of an energy transfer coil includes the following steps:

[0030] S1: Perform leak stoppage treatment on the structural member 1. After completion, place the energy transfer coil 2 into the structural member 1.

[0031] S2: After preparing the potting material through glue mixing treatment, pot the place where the energy transfer coil 2 is placed on the structural member 1 to form a potting layer 3.

[0032] S3: After potting is completed, perform curing treatment on the structural member 1, and finally complete the installation after passing the inspection.

[0033] The energy transfer coil 2 includes a coil body 4 and a fixing body 5. The coil body 4 and the fixing body 5 are connected. There is a gap greater than 5 mm between the outer edge of the coil body 4 and the outer edge of the fixing body 5. The energy transfer coil 2 does not contact the structural member 1. The structural member 1 is a metal structural member. The distance between the bottom of the energy transfer coil 2 and the structural member 1 is ≥ 2 mm, and the distance between the periphery of the energy transfer coil 2 and the structural member 1 is ≥ 5 mm to avoid the generation of eddy currents in the coil body 4 by the metal structural member, reduce losses, and improve the energy transfer efficiency.

[0034] The coil body 4 is an exciting wire, and the fixing body 5 is a ferrite. The coil body 4 is obtained by winding an exciting wire with a wire diameter of 0.04 mm * 1000 strands for 3 layers and 8 turns. The length * width * height of the fixing body 5 is 100 mm * 100 mm * 2 mm, and the magnetic flux is 2800.

[0035] A placement groove 6 is provided on the structural member 1. After the energy transfer coil 2 is placed in the placement groove 6, potting is performed to form a potting layer 3. The length * width * height of the placement groove 6 is 105 mm * 105 mm * 12 mm.

[0036] The plugging treatment in step S1 includes the process of plugging the through holes on the structural member 1 with high-temperature tape and silicone rubber. The through holes with a diameter less than 5 mm are plugged with high-temperature tape, and the through holes with a diameter greater than 5 mm are plugged with silicone rubber 704.

[0037] The potting material in step S2 is BEEP 6225 thermosetting potting adhesive, and the available time after preparing the BEEP 6225 silicone rubber by mixing the glue is 120 min.

[0038] Use the BEEP 6225 thermosetting potting adhesive produced by Shanghai Baigao Chemical Technology Co., Ltd. The BEEP 6225 thermosetting potting adhesive is prepared by stirring and mixing components A and B according to the manufacturer's instructions. The mass ratio of component A to component B is 5:1. The glue mixing treatment is carried out in an environment with a temperature of 25°C ± 5°C and a humidity < 70%.

[0039] The steps of the glue mixing treatment are as follows:

[0040] S1: Accurately weigh

[0041] Weigh the base glue component A and the curing agent component B respectively according to the weight ratio stated in the product instructions;

[0042] S2: Mix and stir

[0043] Pour component B into the container of component A;

[0044] Slowly stir clockwise for 5 min to avoid quickly introducing air bubbles. Scratch the cup wall and bottom to ensure there are no dead corners;

[0045] If high transparency is required, vacuum degassing can be carried out;

[0046] Put the mixed glue into a vacuum machine, pump it to -0.1 MPa and keep it for 3 min to eliminate air bubbles, and complete the glue mixing treatment.

[0047] In step S2, first perform potting at the bottom of the placement groove 6 to obtain an initial potting layer with a thickness of 2 mm. During the time when the potting material is not cured, place the energy transfer coil 2 flat and horizontally in the center of the initial potting layer, and then continue potting until the potting material covers the energy transfer coil 2. After potting, the top of the formed potting layer 3 is flush with the surface of the structural member 1. An insulating high-temperature pad with the same thickness can also be used to pad up the energy transfer coil 2 instead of the initial potting layer.

[0048] The curing treatment includes two curing processes. The first curing is carried out after potting, and the first curing is to keep it at 70°C for 2 h. The second curing is to keep it at 90°C for 2 h.

[0049] The first curing needs to be carried out within 2 hours after the potting. The two curing treatments need to be carried out using different curing equipment respectively. During the baking process, the structural member 1 should be prevented from tilting, falling, etc.

[0050] The testing step includes using a brush dipped in anhydrous ethanol to brush back and forth 5-10 times on the same position on the surface of the encapsulation layer 3. The encapsulation layer 3 is qualified if there is no delamination, peeling, or flow.

[0051] Example 2:

[0052] like Figures 1 to 3 As shown, a method for installing an energy transfer coil includes the following steps:

[0053] S1: Perform leak-proofing treatment on structural component 1. After completion, place energy transfer coil 2 into structural component 1.

[0054] S2: After preparing the potting material by adjusting the glue, the energy transmission coil 2 is placed on the structural part 1 and potting is performed to form a potting layer 3.

[0055] S3: After potting is completed, the structural component 1 is cured and finally installed after passing the inspection.

[0056] The energy transmission coil 2 includes a coil body 4 and a fixed body 5. The coil body 4 and the fixed body 5 are connected. There is a gap greater than 5 mm between the outer edge of the coil body 4 and the outer edge of the fixed body 5. The energy transmission coil 2 does not contact the structural part 1. The structural part 1 is a metal structural part. The distance between the bottom of the energy transmission coil 2 and the structural part 1 is ≥2 mm, and the distance between the energy transmission coil 2 and the structural part 1 is ≥5 mm to avoid eddy currents generated by the metal structural part on the coil body 4, reduce losses, and improve energy transmission efficiency.

[0057] The coil body 4 is an excitation wire, and the fixed body 5 is a ferrite. The coil body 4 is wound with 3 layers and 8 turns of 0.04mm*1000 strands of excitation wire. The fixed body 5 has a length*width*height of 100mm*100mm*2mm and a magnetic flux of 2800.

[0058] The structural member 1 is provided with a placement groove 6, and the energy transmission coil 2 is placed in the placement groove 6 and then potted to form a potting layer 3. The placement groove 6 has a length * width * height of 105mm * 105mm * 12mm.

[0059] The sealing treatment in step S1 includes using high temperature tape and silicone rubber to seal the through holes on the structural member 1. High temperature tape is used to seal through holes with a diameter less than 5 mm, and silicone rubber 704 is used to seal through holes with a diameter greater than 5 mm.

[0060] The potting material in step S2 is BEEP 6225 thermosetting potting adhesive, and the available time after preparing BEEP 6225 silicone rubber by mixing the glue is 120 minutes.

[0061] Use the BEEP 6225 thermosetting potting adhesive produced by Shanghai Baigao Chemical Technology Co., Ltd. This BEEP 6225 thermosetting potting adhesive is prepared by stirring and mixing components A and B according to the manufacturer's instructions. The mass ratio of component A to component B is 5:1. The glue mixing treatment is carried out in an environment with a temperature of 25°C ± 5°C and a humidity of <70%.

[0062] The steps of the glue mixing treatment are as follows:

[0063] S1: Accurately weigh

[0064] Weigh the base glue component A and the curing agent component B respectively according to the weight ratio stated in the product instructions.

[0065] S2: Mix and stir

[0066] Pour component B into the container of component A.

[0067] Slowly stir clockwise for 5 minutes to avoid quickly introducing air bubbles. Scratch the inner wall and bottom of the cup to ensure there are no dead corners.

[0068] If high transparency is required, vacuum degassing can be carried out.

[0069] Put the mixed glue into a vacuum machine, evacuate to -0.1 MPa and hold for 3 minutes to eliminate air bubbles, and complete the glue mixing treatment.

[0070] In step S2, first perform potting at the bottom of the placement groove 6 to obtain an initial potting layer with a thickness of 2 mm. During the uncured time of the potting material, place the energy transfer coil 2 flat and horizontally at the center of the initial potting layer, and then continue potting until the potting material covers the energy transfer coil 2. After potting is completed, the top of the potting layer 3 is flush with the surface of the structural member 1. An insulating high-temperature pad with the same thickness can also be used to pad up the energy transfer coil 2 instead of the initial potting layer.

[0071] The curing treatment includes two curing processes. The first curing is carried out after potting, and the first curing is to hold at 90°C for 3 hours. The second curing is to hold at 110°C for 3 hours.

[0072] The first curing needs to be carried out within 2 hours after potting. The two curing processes need to use different curing equipment respectively. During the baking process, avoid phenomena such as the structural member 1 being skewed or toppled.

[0073] The detection step includes using a brush to dip in anhydrous ethanol and brush back and forth 5 - 10 times at the same position on the surface of the potting layer 3. If there is no delamination, peeling, or flowing phenomenon on the potting layer 3, it is qualified.

[0074] Example 3:

[0075] As Figures 1 to 3 shown, a method for installing a power transmission coil includes the following steps:

[0076] S1: Plug the leak of the structural member 1. After completion, place the power transmission coil 2 into the structural member 1.

[0077] S2: After preparing the potting material through glue mixing treatment, pot the place where the power transmission coil 2 is placed on the structural member 1 to form a potting layer 3.

[0078] S3: After potting is completed, cure the structural member 1, and finally complete the installation after passing the inspection.

[0079] The power transmission coil 2 includes a coil body 4 and a fixing body 5. The coil body 4 and the fixing body 5 are connected. There is a gap greater than 5 mm between the outer edge of the coil body 4 and the outer edge of the fixing body 5. The power transmission coil 2 does not contact the structural member 1. The structural member 1 is a metal structural member. The distance between the bottom of the power transmission coil 2 and the structural member 1 is ≥ 2 mm, and the distance between the periphery of the power transmission coil 2 and the structural member 1 is ≥ 5 mm to avoid the generation of eddy currents in the coil body 4 by the metal structural member, reduce losses, and improve the power transmission efficiency.

[0080] The coil body 4 is an exciting wire, and the fixing body 5 is a ferrite. The coil body 4 is obtained by winding an exciting wire with a wire diameter of 0.04 mm * 1000 strands for 3 layers and 8 turns. The length * width * height of the fixing body 5 is 100 mm * 100 mm * 2 mm, and the magnetic flux is 2800.

[0081] A placement groove 6 is provided on the structural member 1. After the power transmission coil 2 is placed in the placement groove 6, potting is carried out to form a potting layer 3. The length * width * height of the placement groove 6 is 105 mm * 105 mm * 12 mm.

[0082] The plugging treatment in step S1 includes the process of plugging the through holes on the structural member 1 using high-temperature tape and silicone rubber. Through holes with a diameter less than 5 mm are plugged with high-temperature tape, and through holes with a diameter greater than 5 mm are plugged with silicone rubber 704.

[0083] The potting material in step S2 is BEEP 6225 thermosetting potting adhesive, and the available time after preparing BEEP 6225 silicone rubber through glue mixing treatment is 120 min.

[0084] Use the BEEP 6225 thermosetting potting adhesive produced by Shanghai Baigao Chemical Technology Co., Ltd. This BEEP 6225 thermosetting potting adhesive is prepared by stirring and mixing components A and B according to the manufacturer's instructions. The mass ratio of component A to component B is 5:1. The glue mixing treatment is carried out in an environment with a temperature of 25 °C ± 5 °C and a humidity < 70%.

[0085] The steps for glue mixing treatment are as follows:

[0086] S1: Precise weighing

[0087] Weigh the base glue component A and the curing agent component B respectively according to the weight ratio specified in the product instructions;

[0088] S2: Mixing and stirring

[0089] Pour component B into the container of component A;

[0090] Slowly stir clockwise for 5 minutes, avoiding introducing air bubbles quickly, and scrape the inner wall and bottom of the cup to ensure there are no dead corners;

[0091] If high transparency is required, vacuum degassing can be carried out;

[0092] Put the mixed glue into a vacuum machine, evacuate to -0.1 MPa and maintain for 3 minutes to eliminate air bubbles, and complete the glue mixing treatment.

[0093] In step S2, first perform potting at the bottom of the placement groove 6 to obtain an initial potting layer with a thickness of 2 mm. During the time when the potting material is not cured, place the energy transfer coil 2 flat and horizontally at the center of the initial potting layer, and then continue potting until the potting material covers the energy transfer coil 2. After potting is completed, the top of the formed potting layer 3 is flush with the surface of the structural member 1. An insulating high-temperature pad with the same thickness can also be used to pad up the energy transfer coil 2 instead of the initial potting layer.

[0094] The curing treatment includes two curing processes. The first curing is carried out after potting, which is to maintain at 80 °C for 2.5 h, and the second curing is to maintain at 100 °C for 2.5 h.

[0095] The first curing needs to be carried out within 2 hours after potting. The two curing processes need to use different curing equipment respectively, and avoid phenomena such as skewing and toppling of the structural member 1 during the baking process.

[0096] The detection step includes using a brush to dip anhydrous ethanol and brush back and forth 5 - 10 times at the same position on the surface of the potting layer 3. If there is no delamination, peeling, or flowing phenomenon on the potting layer 3, it is qualified.

[0097] Use the methods of Examples 1 - 3 to manufacture energy transfer coils, make two for each example, and conduct tests. The two energy transfer coils prepared in the same example are 20 mm apart, and the energy transfer efficiency is 86% when tested at 200 W.

[0098] The list of test equipment is as follows:

[0099]

[0100] Test steps:

[0101] S1: System setup: Coil alignment: Ensure that L1 / L2 are completely coaxial with an offset ≤ 0.5 mm.

[0102] S2: Set the input power: The power supply is in constant voltage mode. Set the input voltage to 28 V and the current limit to 10 A.

[0103] S3: Set the output load: The current is in constant current mode. Set the current A2 to 7.2 A.

[0104] S4: Turn on the power supply: Record the power supply voltage as 28 V and the power supply current A1.

[0105] S5: Record the load: The load current is A2 and the load voltage is: V1.

[0106] S6: Calculate the efficiency: (V1 * A2) / (28 * A1) = energy transfer efficiency.

[0107] The obtained results are as follows:

[0108]

[0109] The energy transfer coil prepared by the present invention has a high energy transfer efficiency after being installed on a metal structural member.

Claims

1. A method for installing a power transmission coil, characterized in that It includes the following steps: S1: Plug the leak of the structural member (1). After completion, place the energy transfer coil (2) into the structural member (1). S2: After preparing the potting material through glue mixing treatment, pot the place where the energy transfer coil (2) is placed on the structural member (1) to form a potting layer (3). S3: After potting, conduct a curing treatment on the structural member (1). Finally, complete the installation after passing the inspection.

2. The installation method of a power transfer coil as claimed in claim 1, characterized in that: The energy transfer coil (2) includes a coil body (4) and a fixing body (5). The coil body (4) is connected to the fixing body (5). There is a gap between the outer edge of the coil body (4) and the outer edge of the fixing body (5). The energy transfer coil (2) does not contact the structural member (1).

3. The installation method of a power transfer coil according to claim 2, characterized in that: The coil body (4) is an exciting wire, and the fixing body (5) is a ferrite.

4. The installation method of a power transfer coil according to claim 1, characterized in that: A placement groove (6) is provided on the structural member (1). After the energy transfer coil (2) is placed into the placement groove (6), potting is carried out to form a potting layer (3).

5. The installation method of a power transfer coil according to claim 1, characterized in that: The leak plugging treatment in step S1 includes the process of plugging the through holes on the structural member (1) using tape and silicone rubber.

6. The installation method of a power transmission coil according to claim 1, characterized in that: The potting material in step S2 is BEEP 6225 thermosetting potting adhesive. The available time after preparing BEEP 6225 silicone rubber through glue mixing treatment is 120 min.

7. The installation method of a power transfer coil according to claim 1 or 4, characterized in that: In step S2, first pot at the bottom of the placement groove (6) to obtain an initial potting layer. During the time when the potting material is not cured, place the energy transfer coil (2) flat and horizontally at the center of the initial potting layer, and then continue potting until the potting material covers the energy transfer coil (2). The top of the potting layer (3) formed after potting is flush with the surface of the structural member (1).

8. The installation method of a power transmission coil according to claim 1, characterized in that: The curing treatment includes two curing processes. The first curing is carried out after potting and is to maintain at 80 ± 10 °C for 2 - 3 h. The second curing is to maintain at 100 ± 10 °C for 2 - 3 h.

9. The installation method of a power transmission coil according to claim 8, characterized in that: The first curing needs to be carried out within 2 h after potting. The two curing processes need to use different curing equipment respectively.

10. The installation method of a power transfer coil according to claim 1, characterized in that: The inspection step includes using a brush to dip anhydrous ethanol and brush back and forth 5 - 10 times at the same position on the surface of the potting layer (3). If there is no delamination, peeling, or flowing phenomenon on the potting layer (3), it is qualified.

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