F101219 |  Li-Polymer battery charger

Regulus was contracted to provide the full range of works, including: 

  • design-to-production analysis

  • production methods selection

  • alternative technologies testing

  • moulds and tools development

  • pre-production prototyping 

  • trial small production, including mechical components and electronics PCBA

  • mass quantity manufacturing, including mechanical components, PCBA and other accessories

Project Details

■ Application : Power Supply for Charging Device

■ Materials Applied 

1. Housing : Aluminum alloy ADC-12

2. Metal parts : 

    a) Brass

    b) Spring steel, SK7

    c) Stainless steel, SUS304

3. Plastic parts : PC, Transparent PC-108U 

4. Silicone & Rubber parts : 

    a) Silicone, SH518OU

    b) Silicone, Elastosil R401/50 Wacker Chemie AG

    c) Thermally conductive elastic insulating material sheet ; Thermal conductivity, at least 0.80W

5. Cables : UL10102 24AWG, -60℃~200℃, 300V power cable with G31K0S Fmale ODU onnector

6. PCB : Laminate, FR4 High Tg

■ Method of Production  

1. Die casting & Secondary Machining 

    1) Die casting

    2) CNC

    3) Vibrating Finishing

    4) Trimming

    5) Drilling

    6) Tapping

2. Plastic injection molding 

3. CNC Machining 

4. PCBA parts purchasing 

5. PCBA assembly

 

■ Plating & Coating : Cu 3um + Nickel 6um + Matte tin 9um ; Nickel 3um ; Zinc 6um

■ Surface Painting & Coating : Soft-touch painting

■ Surface Final Finishing : Laser engraving 

■ Pre-delivery Processes  

1. Paint adhesion testing

2. Product final assembly

3. Salt spray testing for final product

4. Thermal shock testing for final product

5. Vibration testing for final product

6. Low/high temperature testing for final product

7. Waterproof testing for final product

8. Programming

9. OQC control

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