CN112332551B - 一种无线充电线圈的散热结构及其制造方法 - Google Patents
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Abstract
本发明涉及一种无线充电线圈的散热结构及其制造方法，无线充电线圈的散热结构，其特征在于，包括绝缘板和填充于绝缘板网孔内的填充胶；所述绝缘板与无线充电线圈接触的部分形成均匀分布的网孔；所述绝缘板为绝缘材质，填充胶为绝缘且具有一定导热性能的胶体；所述绝缘板设置在无线充电线圈与磁芯之间。本发明的散热结构既保证了线圈与磁芯之间的绝缘要求，又提升了线圈与磁芯之间的导热性能；既保证了刚度满足要求，又满足了绝缘和导热性能的要求。本发明的散热结构可加工性强，易于实现，安装非常方便。
Description
技术领域
本发明涉及线圈散热技术领域，尤其涉及一种无线充电线圈的散热结构及其制造方法。
背景技术
户外无线充电产品，耦合机构即线圈，为满足防水防尘要求，一般防护等级要达到IP67及以上，线圈热量要通过粘贴在铝材质壳体上面的磁芯进行传递。传统的散热结构中线圈与磁芯之间多为1mm或者2mm绝缘材料，绝大部分绝缘材料具有耐温隔热的特点，导热系数极低，不能满足线圈散热需求，在无线充电系统运行中线圈内部产生大量热量，线圈与磁芯之间的绝缘基板会阻断大部分热量向磁芯传递，导致热量积聚，线圈温度上升。高温破坏线圈自身漆包层的绝缘性能，损坏线圈内部绝缘结构，影响线圈的使用寿命，进而影响整个无线充电系统的运行。这也是目前无线充电亟待解决的问题。
对于小功率的产品可以采用硅胶导热，然而对于大功率产品，硅胶的强度无法满足要求。因此必须采取更有效的散热措施，满足越来越大功率的无线充电产品。
发明内容
针对无线充电产品的散热问题，尤其是大功率无线充电产品的散热的问题，本发明提供一种无线充电线圈的散热结构及其制造方法，强度高，散热性能良好，可加工性强，安装方便，既保证了线圈与磁芯之间的绝缘要求，满足强度要求，又提升了线圈与磁芯之间的导热性能。
为达到上述目的，本发明提供了一种无线充电线圈的散热结构，包括绝缘板和填充于绝缘板网孔内的填充胶；所述绝缘板与无线充电线圈接触的部分形成均匀分布的网孔；所述绝缘板为绝缘材质，绝缘强度大于5000V/mm，弯曲强度大于40Kgf/mm2，抗拉强度大于20Kgf/mm2，耐温大于180℃，所述填充胶为绝缘且具有一定导热性能的胶体；所述绝缘板设置在无线充电线圈与磁芯之间。
进一步地，所述绝缘板与无线充电线圈接触的部分，为网孔结构，开孔率大于50％。
进一步地，所述网孔的尺寸为3～5mm。
进一步地，所述绝缘板为环氧树脂材质，厚度为2mm。
进一步地，所述胶体为环氧灌封胶，导热系数大于0.5W/m·k，固化在所述网孔内；填充后与绝缘板表面齐平。
本发明了另一方面提供一种所述的无线充电线圈的散热结构的制造方法，包括：
在所述绝缘板上标记与无线充电线圈接触的部分，并在与无线充电线圈接触的部分加工均匀分布的网孔；
将环氧灌封胶液体，按固化比例混合；
将所述绝缘板放置在真空灌胶工装内，将胶体填充至网孔，并进行固化。
进一步地，真空环境下灌注固化。
进一步地，环氧灌封胶采用EP3529与EY3528，混合体积比为6:1。
本发明的上述技术方案具有如下有益的技术效果：
(1)本发明的散热结构既保证了线圈与磁芯之间的绝缘要求，又提升了线圈与磁芯之间的导热性能；既保证了刚度满足要求，又满足了绝缘和导热性能的要求。
(2)本发明的散热结构可加工性强，易于实现，安装非常方便。
(3)本发明的散热结构刚度较高，适用范围广，尤其能够适用于汽车无线充电线圈等大功率充电线圈。
附图说明
图1为本发明的散热结构布局示图；
图2为本发明的散热结构爆炸示图；
图3为散热结构网孔结构示意图。
具体实施方式
为使本发明的目的、技术方案和优点更加清楚明了，下面结合具体实施方式并参照附图，对本发明进一步详细说明。应该理解，这些描述只是示例性的，而并非要限制本发明的范围。此外，在以下说明中，省略了对公知结构和技术的描述，以避免不必要地混淆本发明的概念。
提供一种无线充电线圈的散热结构，如图1、图2所示，包括绝缘板1和填充于绝缘板1网孔内的填充胶5。
产生磁场的线圈2和增强磁场的磁芯3之间设置绝缘板。磁芯3固定至磁芯固定的铝板壳体4。通过填充胶5将热量传到至磁芯3，由磁芯3传到至铝板壳体4散热。
如图3所示，所述绝缘板1为具有一定强度的网孔结构，网孔均匀布置于线圈绕线轨迹下方。
所述填充胶5均匀填充于网孔内，固化后与绝缘板1形成一个整体。绝缘板1相较于硅胶垫强度更好，例如可以采用环氧树脂材质。经机加形成网孔，作为一个完整的具有一定强度的骨架，填充胶体。
进一步地，所述绝缘板与无线充电线圈接触的部分，开孔率大于50％，一方面保证传热性能，另一方面保证骨架整体结构的钢性满足要求。
所述填充胶5为具有一定导热性能的胶体，胶体为环氧灌封胶，导热系数大于0.5W/m·k。例如采用EP3529与EY3528混合。填充后与绝缘板表面齐平。
工作时，线圈2产生的热量通过绝缘板1网孔内的填充胶5，将热量快速的传递到磁芯3，进而磁芯3将热量传导至铝板壳体4，完成线圈2的热量传递。
使用时仅需将填充过填充胶5的绝缘板1，铺放在磁芯3的上方即可。
本发明另一方面提供一种无线充电线圈的散热结构的制造方法，包括：
在所述绝缘板1上标记与无线充电线圈2接触的部分，并在与无线充电线圈2接触的部分加工均匀分布的网孔；
将环氧灌封胶液体5，按一定比例混合；EP3529与EY3528混合体积比为6:1。
将所述绝缘板1放置在真空灌胶工装内，将胶体5填充至网孔，并进行固化。
所述的制造方法，在真空环境下灌注固化，有效减少胶体5内部气泡数量，提升胶体5致密度，提升导热性能。综上所述，本发明涉及一种无线充电线圈的散热结构及其制造方法，无线充电线圈的散热结构，其特征在于，包括绝缘板和填充于绝缘板网孔内的填充胶；所述绝缘板与无线充电线圈接触的部分形成均匀分布的网孔；所述绝缘板为绝缘材质，填充胶为绝缘且具有一定导热性能的胶体；所述绝缘板设置在无线充电线圈与磁芯之间。本发明的散热结构既保证了线圈与磁芯之间的绝缘要求，又提升了线圈与磁芯之间的导热性能；既保证了刚度满足要求，又满足了绝缘和导热性能的要求。本发明的散热结构可加工性强，易于实现，安装方便。
应当理解的是，本发明的上述具体实施方式仅仅用于示例性说明或解释本发明的原理，而不构成对本发明的限制。因此，在不偏离本发明的精神和范围的情况下所做的任何修改、等同替换、改进等，均应包含在本发明的保护范围之内。此外，本发明所附权利要求旨在涵盖落入所附权利要求范围和边界、或者这种范围和边界的等同形式内的全部变化和修改例。
Claims (7)
1.一种无线充电线圈的散热结构的制造方法，其特征在于，所述散热结构包括绝缘板和填充于绝缘板网孔内的填充胶；所述绝缘板与无线充电线圈接触的部分形成均匀分布的网孔；所述绝缘板为绝缘材质，绝缘强度大于5000V/mm，弯曲强度大于40Kgf/mm2，抗拉强度大于20Kgf/mm2，耐温大于180℃，所述填充胶为绝缘且具有一定导热性能的胶体；所述绝缘板设置在无线充电线圈与磁芯之间；
所述制造方法包括：
在所述绝缘板上标记与无线充电线圈接触的部分，并在与无线充电线圈接触的部分加工均匀分布的网孔；
将环氧灌封胶液体，按固化比例混合；
将所述绝缘板放置在真空灌胶工装内，将环氧灌封胶液体填充至网孔，并进行固化。
2.根据权利要求1所述的制造方法，其特征在于，所述绝缘板与无线充电线圈接触的部分，为网孔结构，开孔率大于50％。
3.根据权利要求1或2所述的制造方法，其特征在于，所述网孔的尺寸为3～5mm。
4.根据权利要求3所述的制造方法，其特征在于，所述绝缘板为环氧树脂材质，厚度为2mm。
5.根据权利要求1或2所述的制造方法，其特征在于，所述环氧灌封胶的导热系数大于0.5W/m·k，固化在所述网孔内；填充后与绝缘板表面齐平。
6.根据权利要求1所述的制造方法，其特征在于，真空环境下灌注固化。
7.根据权利要求1所述的制造方法，其特征在于，环氧灌封胶采用EP3529与EY3528，混合体积比为6:1。
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Citations (7)
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