Inductive Charging Device Encapsulation via Solvent-Free Casting
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Solution Overview
Problem
Conventional inductive charging device production methods are hindered by long cycle times, high production costs, occupational safety concerns due to solvent-based casting compounds, and the need for a separate housing as lost formwork, which also complicates bubble-free casting and increases maintenance.
Innovation Solution
The method involves encasing a ferrite and coil in a low-pressure casting, pressing transfer moulding, or injection moulding process, eliminating the need for a separate housing and using solvent-free plastics, which reduces cycle time and costs while ensuring gentle embedding and bubble-free production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional casting compounds are used with slow hardening time, then the casting compound can be processed, but the cycle time increases up to 24 hours
Solution Approach 1:
The patent changes the chemical composition parameters of the casting compound by using solvent-free plastics (polyester resins, vinyl esters, epoxies, polyurethanes, or their blends) instead of conventional solvent-based compounds. This parameter change enables the use of catalytic hardening systems that cure much faster, reducing cycle time from 24 hours to approximately 2 hours while maintaining good castability through controlled viscosity and reactivity.
Solution Approach 2:
The patent employs composite material systems combining specific plastic matrices (polyester, vinyl ester, epoxy, or polyurethane) with tailored catalyst systems and optional fillers. These composite formulations provide both the necessary processing characteristics for good castability and the accelerated hardening kinetics required to reduce cycle time, achieving a balance between manufacturability and productivity.
2Ease of manufacture
If solvent-based casting compounds are used, then the casting compound can be processed, but occupational safety measures are required due to solvent emissions
Solution Approach 1:
The patent eliminates the harmful solvents from the casting compound formulation entirely, replacing them with solvent-free plastic matrices. This converts the harmful emission problem into a benefit by providing a safer working environment while maintaining or improving processability through controlled viscosity and catalytic hardening mechanisms that enable complete filling of molds.
Solution Approach 2:
The patent creates an inert or at least non-harmful processing environment by using solvent-free formulations. The casting compounds based on polyester resins, vinyl esters, epoxies, or polyurethanes without volatile organic solvents eliminate the need for complex ventilation and occupational safety infrastructure, while the controlled chemical reactions provide sufficient working time for complete mold filling.
3Reliability
If a separate housing is used as lost formwork, then the ferrite and coil can be protected, but the variety of parts increases and production costs rise
Solution Approach 1:
The patent merges the protective housing function directly into the casting compound itself. The solvent-free casting compound encapsulates the ferrite and coil components, providing mechanical protection, electrical insulation, and structural integrity in a single integrated element. This eliminates the need for separate housing parts while maintaining comprehensive component protection.
Solution Approach 2:
The casting compound is designed to perform multiple functions simultaneously: it serves as the encapsulating medium, the protective housing, the structural support, and the adhesive bonding agent. This multi-functional approach eliminates the need for separate housing components and reduces the total part count while ensuring reliable protection of the ferrite and coil assemblies.
4Ease of manufacture
If conventional casting installations are used, then the casting can be performed, but the installations are expensive and maintenance-intensive
Solution Approach 1:
The patent employs disposable or easily replaceable mold inserts and simple casting fixtures that do not require complex temperature control systems, vacuum equipment, or sophisticated maintenance infrastructure. The solvent-free casting compounds can be processed using straightforward pouring or injection techniques into simple molds, eliminating the need for expensive, maintenance-intensive conventional casting installations while maintaining good castability.
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
This approach significantly reduces production time and costs, enhances product quality, and simplifies the process by eliminating the need for solvent-based materials and separate housings, resulting in a more efficient and safer manufacturing method for inductive charging devices.
Implementation Method 1
encasing at least partially with plastic the ferrite and the coil, wound from a braid, in a low pressure casting method
Implementation Method 2
encasing at least partially with plastic the ferrite and the coil, wound from a braid, in a pressing transfer moulding method
Implementation Method 3
encasing at least partially with plastic the ferrite and the coil, wound from a braid, in an injection moulding method
Implementation Method 4
the casting compounds which are used require a comparatively long hardening time of up to 24 hours
Data Source
AI summary
A method for producing an inductive charging device may include inserting a ferrite and a coil, wound from a braid, into a mould; and encasing the ferrite and the braid at least partially with a plastic in a low pressure casting method, a pressing transfer moulding method, or an injection moulding method.