Elastomer Coated Magnetic Ferrite Impact Resistance
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional magnetic ferrites used in wireless power transmission devices are vulnerable to physical impact, leading to reduced magnetic properties and increased loss rates, and suffer from delamination due to thermal expansion differences when adhered to substrates.
Innovation Solution
A coating of elastomer composition comprising epoxy resin, acrylate resin, organic and inorganic fillers, cross-linking agents, hardeners, initiators, and solvents is applied to the magnetic ferrite, providing elastic restoring force, thermal stability, and compensating for expansion differences with substrates.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional magnetic ferrite sintered compact is used, then magnetic properties are achieved, but impact resistance is poor leading to damage and reduced magnetic properties
Solution Approach 1:
The patent applies a coating layer to the magnetic ferrite sintered compact before it is installed in the wireless power transmission device. This coating layer acts as a cushioning layer that absorbs and distributes impact forces, preventing direct impact damage to the magnetic ferrite. The coating is applied in advance as a protective measure, which is the essence of beforehand cushioning - preparing protective measures before the harmful impact occurs.
Solution Approach 2:
The patent creates a composite structure by coating the magnetic ferrite sintered compact with a protective material layer. This composite structure combines the magnetic properties of the ferrite with the mechanical protection of the coating material, achieving both magnetic functionality and impact resistance. The coating layer and magnetic ferrite form a composite material system where each component contributes its superior properties.
2Strength
If magnetic ferrite is adhered to substrate, then structural support is provided, but delamination occurs due to thermal expansion differences
Solution Approach 1:
The patent introduces a coating layer as an intermediary between the magnetic ferrite sintered compact and the substrate. This intermediate layer has thermal expansion properties that are compatible with both the magnetic ferrite and the substrate, acting as a buffer that absorbs thermal expansion differences. This prevents delamination by mediating the thermal stress between the two materials with different expansion coefficients.
Solution Approach 2:
The patent specifically addresses thermal expansion differences by selecting a coating material whose thermal expansion coefficient lies between that of the magnetic ferrite and the substrate. This allows the coating layer to accommodate thermal expansion variations during operation, preventing stress concentration and delamination that would occur if the magnetic ferrite were directly adhered to the substrate with mismatched expansion properties.
3Ease of operation
If physical impact is applied to magnetic ferrite, then device operation continues, but magnetic properties are reduced and loss rates increase
Solution Approach 1:
The coating layer is applied beforehand to protect the magnetic ferrite from impact damage. By absorbing and distributing impact forces, the coating prevents the magnetic ferrite from suffering damage that would reduce its magnetic properties and increase energy losses. This allows the device to maintain low loss rates and high efficiency even in environments where physical impacts may occur.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The coated magnetic ferrite exhibits improved impact resistance and prevents delamination, maintaining high permeability and low loss rates in wireless power transmission devices.
Implementation Method 1
an elastomer composition for coating a magnetic ferrite, the composition including: epoxy resin; acrylate resin; an organic filler; an inorganic filler; a cross linking agent; a hardener; an initiator; and a solvent
Implementation Method 2
compensating for expansion differences with substrates
Data Source
AI summary
Provided are an elastomer composition including epoxy resin, acrylate resin, an organic filler, an inorganic filler, a cross linking agent, a hardener, an initiator and a solvent, and a magnetic ferrite for a wireless power transmitting and receiving device, the magnetic ferrite being coated with the elastomater composition having an elastic restoring force not to be damaged by a physical impact applied from the outside.According to embodiments of the present invention, the magnetic ferrite having improved impact resistance can be provided by being coating with the elastomer composition having the elastic restoring force, and thus an existing problem such as a reduction in magnetic property caused by damage to the ferrite resulting from an external impact can be solved.