Integrated Sendust Block for Wireless Power Chargers
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Solution Overview
Problem
Conventional sendust blocks in wireless power transmitters have poor insulating properties, requiring separate insulating sheets and limiting integration of electronic parts and terminals, which is a challenge for robustness and efficiency in applications like vehicle-mounted wireless charging systems that need high magnetic permeability and durability.
Innovation Solution
A method of manufacturing a sendust block with high insulating performance and magnetic permeability involves forming flake powder with an oxide film through oxygen heat treatment, applying chemical additives for surface insulation, mixing with insulative resin powder, and injection molding to create a block with integrated terminals, enhancing assembly and durability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional sendust blocks are used in wireless power transmitters, then magnetic shielding is provided, but insulating properties are poor requiring separate insulating sheets
Solution Approach 1:
The patent combines the magnetic shielding function and electrical insulation function into a single integrated sendust block structure. The sendust block inherently provides both magnetic shielding properties and electrical insulation properties, eliminating the need for separate insulating sheets and reducing structural complexity while maintaining reliability.
Solution Approach 2:
The sendust block is formed using composite material technology, combining magnetic metal particles (sendust) with insulating resin or binder materials. This composite structure provides both the magnetic shielding characteristics of sendust and the electrical insulation properties of the resin, resolving the contradiction between magnetic shielding performance and insulating properties.
2Adaptability or versatility
If conventional sendust blocks are used, then magnetic shielding is achieved, but integration of electronic parts and terminals is limited
Solution Approach 1:
The patent integrates electronic parts, terminals, and magnetic shielding functionality into a single unified sendust block structure. This allows electronic components to be directly embedded within the magnetic shielding block, improving adaptability and integration capability while the inherent insulation properties of the sendust block maintain reliability.
3Reliability
If conventional sendust blocks are used in vehicle-mounted systems, then magnetic shielding is provided, but robustness to vibration is insufficient
Solution Approach 1:
The patent merges multiple components (magnetic shielding block, electronic parts, terminals, and insulating structures) into a single integrated sendust block. This integration significantly improves robustness to vibration by eliminating separate components that could loosen or detach, while also simplifying the overall assembly process and reducing assembly complexity.
4Reliability
If separate insulating sheets are attached to sendust blocks, then insulation is improved, but assembly complexity increases
Solution Approach 1:
The patent combines the insulating function directly into the sendust block structure itself, either through the inherent insulation properties of the sendust material or by integrating insulating features during the manufacturing process. This eliminates the need for separate insulating sheets, thereby simplifying the assembly process while maintaining reliable insulation properties.
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 resulting sendust block achieves improved insulation and magnetic permeability, enabling efficient wireless power transmission with increased durability and robustness, reducing the risk of short-circuits and assembly issues.
Implementation Method 1
forming an oxide film by performing oxygen heat treatment on the surface of the flake powder
Implementation Method 2
sendust block which has high insulating performance of an AC component and high magnetic permeability
Data Source
AI summary
Embodiments provide a magnetic shield for wireless power chargers and a method of manufacturing the same. The method includes forming flake powder having flake-type particles, forming an oxide film by performing oxygen heat treatment on the surface of the flake powder, performing insulation treatment on the surface of the flake powder provided with the oxide film formed thereon, and producing a sendust block by mixing and melting the insulation-treated flake powder and insulative resin powder. Therefore, a magnetic shield having high insulation characteristics and magnetic permeability may be provided.