Flexible Ferromagnetic Polymer Composite for Wireless Power Flux Direction
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Solution Overview
Problem
Current flux field directional materials (FFDMs) for wireless power charging are limited by their inflexibility, high cost, and inability to handle high power transfer rates due to low magnetic flake loading and frequency constraints, necessitating the development of more effective and flexible materials capable of concentrating and redirecting magnetic flux efficiently.
Innovation Solution
A polymer composite comprising a thermoplastic polymer network structure and a high loading of soft, ferromagnetic particulate material, achieved through induced phase separation and solvent removal, allowing for high saturation magnetic flux density and improved flexibility, enabling efficient wireless power transfer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If traditional ferrite sheets are used for magnetic flux field directional materials, then magnetic flux concentration capability is achieved, but flexibility is poor and cost is high
Solution Approach 1:
The patent creates a composite material consisting of ferromagnetic particulate material embedded in a polymer matrix. This composite structure combines the magnetic properties of ferromagnetic particles with the flexibility of polymer materials, achieving both magnetic flux concentration capability and flexibility that traditional ferrite sheets cannot provide simultaneously
Solution Approach 2:
The patent changes the physical state and composition parameters by using particulate ferromagnetic material instead of solid ferrite sheets, and selecting polymers with appropriate glass transition temperatures to achieve desired flexibility while maintaining magnetic properties
2Power
If high loading of magnetic flake is used to improve power transfer rate, then power transfer capability is enhanced, but frequency constraints and inflexibility worsen
Solution Approach 1:
The patent uses flexible polymer matrices to encapsulate high loadings of ferromagnetic particles, creating thin films that maintain flexibility even at high magnetic material loadings. This allows the material to adapt to different frequencies and applications while achieving high power transfer rates
Solution Approach 2:
The patent creates a new class of flexible magnetic materials that copy the magnetic flux directing function of traditional rigid materials but with improved flexibility and frequency adaptability through the polymer composite structure
3Ease of manufacture
If ferromagnetic particulate material is used instead of traditional FFDM, then flexibility and cost are improved, but manufacturing precision is challenged
Solution Approach 1:
The patent uses polymer matrices as intermediary materials to distribute and hold ferromagnetic particles in uniform arrangements. The polymer acts as a mediator that simplifies manufacturing by allowing particle incorporation during molding processes while maintaining uniform distribution and precise geometric configurations
4Ease of operation
If polymer composite structure is used to achieve flexibility, then ease of operation is improved, but magnetic flux concentration capability may be reduced
Solution Approach 1:
The patent designs composite materials where ferromagnetic particulate material provides magnetic flux concentration capability while the polymer matrix provides flexibility. The synergistic combination allows both properties to coexist, with the ferromagnetic particles maintaining their magnetic functionality within the flexible polymer structure
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 polymer composite achieves high power wireless charging capabilities with enhanced flexibility and reduced costs by allowing up to 80% volume loading of ferromagnetic material, surpassing the limitations of traditional FFDMs in terms of power transfer and material efficiency.
Implementation Method 1
inducing phase separation of the thermoplastic polymer from the solvent
Implementation Method 2
a soft, ferromagnetic particulate material distributed within the thermoplastic polymer, network structure
Data Source
AI summary
The present disclosure relates to polymer composites that include a thermoplastic polymer, network structure and a soft, ferromagnetic particulate material. The polymer composites may be used, for example, as magnetic flux field directional materials. The present invention also relates to methods of making the polymer composites, e.g. polymer composite sheets, of the present disclosure. In one embodiment, the present disclosure provides a polymer composite including a thermoplastic polymer, network structure; and a soft, ferromagnetic particulate material distributed within the thermoplastic polymer, network structure. The weight fraction of soft, ferromagnetic particulate material may be between 0.80 and 0.98, based on the total weight of the polymer composite and/or the thermoplastic polymer may have a number average molecular weight between 5×104 g/mol to 5×107 g/mol.