US-20260125558-A1 - THERMOSETTING FOAM TYPE BINDER COMPOSITION, MAGNETIC PAD COMPRISING THE SAME, AND WIRELESS CHARGING DEVICE COMPRISING THE SAME

US20260125558A1US 20260125558 A1US20260125558 A1US 20260125558A1US-20260125558-A1

Abstract

A thermosetting foam type binder composition can include a main polymer resin and a foaming agent having a foaming initiation temperature of 70 to 110° C., a foaming rate of 50 to 400%, and a viscosity of 3,000 to 100,000 cP. A magnetic pad can incorporate such thermosetting foam type binder composition. A wireless charging device can incorporate such magnetic pad.

Inventors

Young Min Kim
Jungin LEE
SEUNGMIN HONG
Gwang-Gyu Kim
Kyounghoon KANG
Myoungsoo Chun
Taewook Lim
Yusuk Jung

Assignees

HYUNDAI MOTOR COMPANY
KIA CORPORATION
KCC CORPORATION

Dates

Publication Date: 20260507
Application Date: 20250116
Priority Date: 20241101

Claims (13)

1 . A thermosetting foam type binder composition comprising: a main polymer resin; and a foaming agent having a foaming initiation temperature of 70 to 110° C., a foaming rate of 50 to 400%, and a viscosity of 3,000 to 100,000 cP.
2 . The composition of claim 1 , wherein the main polymer resin and the foaming agent are mixed in a weight ratio for the main polymer resin to the foaming agent in a mixture ratio range of 80:1 to 10:1.
3 . The composition of claim 1 , wherein the main polymer resin is a two-component type polymer resin comprising: a first component comprising vinyldimethylpolysiloxane; and a second component comprising organohydrogenpolysiloxane.
4 . The composition of claim 3 , wherein the first component further comprises dimethylpolysiloxane, and wherein the second component further comprises vinyldimethylpolysiloxane.
5 . The composition of claim 4 , wherein the first component comprises: 25 to 35 parts by weight of vinyldimethylpolysiloxane, and 1 to 10 parts by weight of dimethylpolysiloxane; and wherein the second component comprises: 20 to 30 parts by weight of vinyldimethylpolysiloxane, and 5 to 15 parts by weight of organohydrogenpolysiloxane.
6 . The composition of claim 1 , wherein the foaming agent comprises at least one selected from the group consisting of azo-based, hydrazide-based, inorganic-based, and microcapsule-based foaming agents.
7 . The composition of claim 1 , wherein the foaming agent is a capsule-type foaming agent having a particle size of 10 to 30 μm.
8 . A magnetic pad comprising: 1.5 to 7 parts by weight of a thermosetting foam type binder composition comprising: a main polymer resin, and a foaming agent having a foaming initiation temperature of 70 to 110° C., a foaming rate of 50 to 400%, and a viscosity of 3,000 to 100,000 cP.
9 . The magnetic pad of claim 8 , wherein the main polymer resin is a two-component type polymer resin comprising: a first component comprising vinyldimethylpolysiloxane, wherein the first component further comprises dimethylpolysiloxane, and wherein the first component comprises: 25 to 35 parts by weight of vinyldimethylpolysiloxane, and 1 to 10 parts by weight of dimethylpolysiloxane; and a second component comprising organohydrogenpolysiloxane, wherein the second component further comprises vinyldimethylpolysiloxane, and wherein the second component comprises: 20 to 30 parts by weight of vinyldimethylpolysiloxane, and 5 to 15 parts by weight of organohydrogenpolysiloxane.
10 . The magnetic pad of claim 9 , wherein the foaming agent comprises at least one selected from the group consisting of azo-based, hydrazide-based, inorganic-based, and microcapsule-based foaming agents, wherein the foaming agent is a capsule-type foaming agent having a particle size of 10 to 30 μm, wherein the main polymer resin and the foaming agent are mixed in a weight ratio for the main polymer resin to the foaming agent in a mixture ratio range of 80:1 to 10:1.
11 . A wireless charging device comprising the magnetic pad according to claim 8 .
12 . The wireless charging device of claim 11 , wherein the main polymer resin is a two-component type polymer resin comprising: a first component comprising vinyldimethylpolysiloxane, wherein the first component further comprises dimethylpolysiloxane, and wherein the first component comprises: 25 to 35 parts by weight of vinyldimethylpolysiloxane, and 1 to 10 parts by weight of dimethylpolysiloxane; and a second component comprising organohydrogenpolysiloxane, wherein the second component further comprises vinyldimethylpolysiloxane, and wherein the second component comprises: 20 to 30 parts by weight of vinyldimethylpolysiloxane, and 5 to 15 parts by weight of organohydrogenpolysiloxane.
13 . The wireless charging device of claim 12 , wherein the foaming agent comprises at least one selected from the group consisting of azo-based, hydrazide-based, inorganic-based, and microcapsule-based foaming agents, wherein the foaming agent is a capsule-type foaming agent having a particle size of 10 to 30 μm, and wherein the main polymer resin and the foaming agent are mixed in a weight ratio of 80:1 to 10:1.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS This present application claims the benefit of priority to Korean Patent Application No. 10-2024-0153507, filed on Nov. 1, 2024, in the Korean Intellectual Property Office, the entire disclosure of which is incorporated herein by reference. TECHNICAL FIELD The present disclosure relates to a thermosetting foam type binder composition, a magnetic pad comprising the same, and a wireless charging device comprising the same. BACKGROUND Recently, due to the supply expansion of electric vehicles, there is increasing interest in wireless charging technology capable of free charging of batteries without a wired charger. The wireless charging technology basically consists of a transmitter that transmits power and a receiver that receives the transmitted power, and these transmitter and receiver are composed of coils and magnetic materials. The magnetic material used herein is one of key components that determine the efficiency of wireless charging, and is provided in a wireless charging device in the form of a pad. Ferrite tiles were mainly applied to these magnetic pads, but ferrite tile magnetic materials are strongly brittle due to the nature of ceramic tiles to be vulnerable to impacts, and have a disadvantage of making it difficult to be manufactured in a three-dimensional shape. In particular, in the case of a receiver (vehicle) of a wireless charging system for electric vehicles, there is a disadvantage that the ferrite tile magnetic material may be easily damaged by vibration and external impact while driving. To overcome this disadvantage, efforts have been made to manufacture ferrite magnetic materials that are resistant to external impact. In particular, research has been conducted on flexible materials capable of replacing strongly brittle ferrite tiles, and research has also been actively conducted on binders optimized for these materials. SUMMARY The present disclosure relates to a thermosetting foam type binder composition, a magnetic pad including the same, and a wireless charging device including the same, and more particularly, to a thermosetting foam type binder composition having thermosetting and foaming characteristics, including a main polymer resin and a foaming agent, a magnetic pad including the same, and a wireless charging device including the same. An embodiment of the present disclosure can solve the above-described problems in the related art, and an embodiment of the present disclosure can provide a thermosetting foam type binder composition that includes a polymer resin and a foaming agent to expand in volume and be cured simultaneously when exposed to heat, thereby exhibiting excellent impact resistance and mechanical properties, a magnetic pad including the same, and a wireless charging device including the same. An embodiment of the present disclosure can provide a thermosetting foam type binder composition including a main polymer resin and a foaming agent, and having a foaming initiation temperature of 70 to 110° C., a foaming ratio of 50 to 400%, and a viscosity of 3,000 to 100,000 cP. An embodiment of the present disclosure can provide a magnetic pad including 65 to 95 parts by weight of magnetic material pellets, 10 to 25 parts by weight of magnetic material powder, and 1.5 to 7 parts by weight of a thermosetting foam type composition according to various embodiments of the present disclosure. An embodiment of the present disclosure can provide a wireless charging device including a magnetic pad according to an embodiment of the present disclosure. According to an embodiment of the present disclosure, in a magnetic pad including a binder composition, volume expansion and curing reaction can occur when molded by pressing or heating. Accordingly, using an embodiment of the present disclosure, it can be possible to secure excellent appearance, mechanical strength, and impact resistance. A magnetic pad according to an embodiment of the present disclosure can have excellent electromagnetic properties and may be resistant to external impact. A binder composition according to an embodiment of the present disclosure can have excellent moldability to improve workability when mixed with ferrite pellets or powder. Therefore, in accordance with an embodiment of the present disclosure, a magnetic pad including such binder composition can also have high design freedom. BRIEF DESCRIPTION OF THE DRAWINGS The above and other features and advantages of example embodiments of the present disclosure can become apparent from the detailed description of the example embodiments in conjunction with the accompanying drawings, in which: FIG. 1 shows images of the appearances observed with the naked eye in Example 5-2 and Comparative Example 3-2 of example embodiments of the present disclosure; FIG. 2 shows images of the appearances observed with the naked eye in Example 1-2 and Comparative Example 4-2 of example embodiments of the present disclosure; and FIG. 3