Wireless power transfer apparatus and method of manufacture

A method of manufacturing a wireless power transfer apparatus comprising:

• providing a first casing portion having a wall with a plurality of projecting members extending from an inner surface of the wall and distributed across at least a portion of the inner surface of the wall, the projecting members comprising elastically deformable plastic that deforms when a compressive force is applied to the first casing portion;
• positioning a coil around the plurality of projecting members, the coil configured to wirelessly receive or transmit power and the wall configured to withstand external compression forces;
• connecting a second casing portion to the first casing portion to form a chamber within which the coil is housed, and
• disposing a potting material within the chamber formed by the first and second casing portions.

A wireless power transfer apparatus comprising:

• first casing means for defining a portion of a chamber, the first casing means having an inner surface;
• a plurality of means for providing internal structural support located on and projecting from the inner surface of the first casing means and distributed across at least a portion of the inner surface of the first casing means, the plurality of means for providing internal structural support comprising elastically deformable plastic that deforms when a compressive force is applied to the first casing means;
• means for conveying electric current, wherein the means for conveying electric current is positioned to extend around the plurality of means for providing internal structural support and is configured to wirelessly receive or transmit power;
• second casing means for defining a further portion of the chamber, the second casing means secured to the first casing means to form the chamber for housing the means for conveying electric current;
• and
• means for potting disposed inside the chamber formed by the first and second casing means.