JP6526542B2 - Coil unit - Google Patents

Description

  The present invention relates to a coil unit for non-contact power feeding used in a power feeding side unit and a power receiving side unit of a non-contact power feeding system in which power is fed from a fixed body side to a movable body such as an electric car in a contactless manner.

  A non-contact power feeding system has been developed and put into practical use, which wirelessly feeds power from a fixed body side to a rechargeable battery mounted on a mobile side such as an electric car. The non-contact power feeding system includes, for example, a power receiving side unit mounted on a vehicle which is a moving body, and a power feeding side unit installed on a fixed body such as a parking space where the vehicle parks.

  According to this non-contact power feeding system, the vehicle is parked in the parking space, and the AC power is supplied to the coil of the power feeding unit with the power receiving unit and the power feeding unit facing each other at an interval. The coil of the power receiving unit can receive the AC power without contact.

Examples of such non-contact power feeding coil units used for the power feeding side unit and the power receiving side unit are known in Patent Document 1 and the like.
For example, the coil unit 501 shown in FIG. 4 has a coil 505 in the non-contact power feeding system, a bottom wall 502 and a peripheral wall 504, and a coil case 503 for housing the coil 505 inside a rectangular housing space opened at the top. The capacitor module 7 disposed at the winding center of the coil 505 wound on the bottom wall 502 along the peripheral wall 504, the magnetic material 508 covering the capacitor module 7, and the lid covering the opening of the coil case 503 And a body 510.

  At a central portion of the bottom wall 502 of the coil case 503, a housing recess 533 in which the pair of capacitor modules 7 is disposed is provided. The capacitor module 7 housed in the housing recess 533 has a substantially rectangular substrate 71 and a plurality of elements 73 mounted on the substrate 71. The capacitor module 7 is, for example, an electrical component that constitutes a foreign matter detection circuit that detects metallic foreign matter around the coil unit 501.

  The magnetic material 508 has a role of protecting the capacitor module 7 (particularly, the upper part of the element 73) from magnetic flux, and one rectangular plate so as to cover the entire capacitor module 7 accommodated in the accommodation recess 533 of the coil case 503. It consists of a ferrite plate of the shape of a circle. The magnetic material 508 is accommodated and positioned in a magnetic material accommodation recess 511 formed on the inner surface of the lid 510.

JP, 2015-153863, A

Incidentally, the magnetic material 508 in the coil unit 501 shown in FIG. 4 is formed of a single rectangular plate-shaped ferrite plate covering the entire pair of capacitor modules 7 disposed at the center of the coil case 503. Since the magnetic material such as the ferrite plate has an upper limit in the size in manufacture, depending on the size, the manufacture itself of a large ferrite plate may be difficult.
In general, ferrite (magnetic material) has a large manufacturing tolerance, and the larger the ferrite, the larger the dimensional variation. Therefore, the magnetic material 508 needs to be polished after firing, which causes a problem of cost increase.
Furthermore, the large-sized magnetic material 508 may generate a crack when a bending stress is applied by an external force applied to the coil unit 501.

  This invention is made in view of the situation mentioned above, The objective is to provide the coil unit for non-contact electric power feeding whose manufacturing cost is cheap.

In order to achieve the above-mentioned object, the coil unit for non-contact electric power feeding concerning the present invention is characterized by the following composition.
(1) A coil case in a noncontact power feeding system, a coil case having a bottom wall and a peripheral wall, and a coil case for accommodating the coil in a housing space opened at the top, and wound on the bottom wall along the peripheral wall A coil unit comprising an electrical component disposed at a winding center of the coil, and a magnetic material covering the electrical component,
A coil unit comprising: a plurality of magnetic plates arranged to be divided at a position not overlapping the element mounted on the electrical component.

According to the coil unit having the above configuration (1), the magnetic material covering the electric component disposed at the winding center (the center of the coil case) of the coil is constituted by a plurality of divided magnetic plates So, the size per piece can be reduced. Therefore, the dimensional variation of the magnetic plate can be reduced to reduce the manufacturing cost. In addition, the plurality of magnetic plates can be divided so as not to overlap the elements, so that even if a gap is generated between adjacent magnetic plates, the shielding effect on the elements can be maintained.
In addition, the plurality of magnetic plates having the divided structure has a gap between the magnetic plates to increase the flexibility and reduce the bending stress acting by the external force applied to the coil unit, thereby preventing the cracking. Can.

(2) A magnetic plate case for accommodating the plurality of magnetic plates arranged in a predetermined position is provided, and the gaps between adjacent magnetic plates do not overlap with the electric component in a plan view. The coil unit according to (1), wherein each of the magnetic plates is housed in each housing portion of the magnetic plate case so that a gap at a position overlapping the electric component in a plan view becomes narrower. .

  According to the coil unit having the above configuration (2), the size of each accommodation portion of the magnetic plate case for accommodating the plurality of magnetic plates arranged in a predetermined position is formed to be slightly larger than the magnetic plate. It can be made easy to accommodate a board. The magnetic plate housed in each housing portion is disposed so that the gap between the magnetic plates at a position overlapping with the electric component in a plan view is narrower than the gap at a position not overlapping with the electric component. Can be maintained. Therefore, the manufacturing accuracy can be further reduced by lowering the assembly accuracy when the magnetic plate is accommodated in each accommodation portion of the magnetic plate case.

  According to the present invention, it is possible to provide a coil unit for non-contact power feeding, which is inexpensive in manufacturing cost, by forming a magnetic material that covers an electrical component with a plurality of divided magnetic plates.

  The present invention has been briefly described above. Furthermore, the details of the present invention will be further clarified by reading the modes for carrying out the invention described below (hereinafter referred to as "embodiments") with reference to the attached drawings. .

(A) is a schematic plan view for demonstrating the coil unit which concerns on one Embodiment of this invention, (b) is an AA cross section arrow line view of (a). It is a disassembled perspective view of the coil unit shown in FIG. (A), (b) is a bottom face for demonstrating the arrangement | positioning of the magnetic board accommodated in the accommodating part of the magnetic board case shown in FIG. (A) is a schematic plan view for demonstrating the conventional coil unit, (b) is a BB cross section arrow line view of (a).

Hereinafter, embodiments of the present invention will be described with reference to the drawings.
(A) of FIG. 1 is a schematic plan view for demonstrating the coil unit 1 which concerns on one Embodiment of this invention, (b) of FIG. 1 is an AA cross section arrow line view of (a) of FIG. It is. In addition, in (a) of FIG. 1, illustration of the magnetic board case 10 is abbreviate | omitted.

  The coil unit 1 shown in FIG. 1 is installed under the floor of a vehicle (mobile body), and is a power receiving side unit or a power feeding side which receives power without contact from a power feeding unit installed on the fixed body side (parking space etc.) not shown. It is a coil unit accommodated and used inside the case of a unit.

  As shown in FIGS. 1 and 2, the coil unit 1 of the present embodiment includes the coil 5 in the non-contact power feeding system, the bottom wall 2 and the peripheral wall 4, and the coil 5 is housed inside the storage space opened at the top. It is a magnetic material that covers the coil case 3 to be accommodated, the capacitor module (electrical component) 7 disposed at the winding center of the coil 5 wound on the bottom wall 2 along the peripheral wall 4, and the capacitor module 7 A plurality of magnetic plates 8 a, 8 b, 8 c, 8 d and a magnetic plate case 10 as a lid covering the opening of the coil case 3 are provided.

  In the central portion of the bottom wall 2 of the coil case 3, a housing recess 33 in which the pair of capacitor modules 7 is disposed is provided. The capacitor module 7 housed in the housing recess 33 has a substantially rectangular substrate 71 and a plurality of elements 73 mounted on the substrate 71. The capacitor module 7 is, for example, an electrical component that constitutes a foreign matter detection circuit that detects metallic foreign matter around the coil unit 1. The electric component of the present invention is not limited to the capacitor module 7 but is applied to various electric components on which various elements that need to be protected from magnetic flux are mounted.

  In the present embodiment, four magnetic plate groups 8 including four magnetic plates 8 a, 8 b, 8 c, 8 d are arranged side by side so as to cover the capacitor module 7. The magnetic plates 8a, 8b, 8c and 8d in the magnetic plate group 8 have a role of protecting the capacitor module 7 (particularly, the upper portion of the element 73) from the magnetic flux, and the capacitor module housed in the housing recess 33 of the coil case 3 It is comprised by several rectangular-plate-shaped ferrite boards so that 7 whole may be covered. Of course, it goes without saying that the magnetic plate in the present invention is not limited to ferrite, and various magnetic materials can be used.

  The magnetic plates 8a, 8b, 8c and 8d in each magnetic plate group 8 have four magnetic material accommodation concave portions (housing portions) 11a and 11b in four sets of magnetic material accommodation portions 11 formed on the inner surface 12 of the magnetic plate case 10. , 11c and 11d, respectively. Further, as shown in FIG. 1, the plurality of magnetic plates 8a, 8b, 8c, 8d are arranged to be divided at positions not overlapping the elements 73 mounted on the capacitor module 7.

  According to such a coil unit 1, the magnetic members covering the pair of capacitor modules 7 disposed at the winding central portion (central portion of the coil case 3) of the coil 5 are divided into a plurality of magnetic plates 8 a and 8 b. , 8c, 8d, the size per sheet can be reduced. Therefore, the dimensional variation of the magnetic plates 8a, 8b, 8c, 8d can be reduced to reduce the manufacturing cost.

The plurality of magnetic plates 8a, 8b, 8c and 8d are arranged to be divided at positions not overlapping the element 73, so that even if gaps 9A and 9B are generated between adjacent magnetic plates, The shielding effect on the element 73 can be maintained.
Further, the plurality of magnetic plates 8a, 8b, 8c, 8d having the divided structure has flexibility by the presence of the gaps 9A, 9B between the magnetic plates, and a bending stress acting by the external force applied to the coil unit 1 Can be reduced to prevent cracking.

  Furthermore, as shown in FIG. 2, on the inner surface 12 of the magnetic plate case 10 of the present embodiment, the gaps 9 B at positions where the gaps 9 A and 9 B between adjacent magnetic plates do not overlap the capacitor module 7 in plan view The magnetic material accommodation recesses 11a, 11b, 11c, 11d for accommodating the magnetic plates 8a, 8b, 8c, 8d are arranged such that the gap 9A at a position overlapping the module 7 in plan view becomes narrower (see FIG. 1). It is formed.

  More specifically, as shown in FIG. 3A, the four magnetic material accommodation concave portions 11a, 11b, 11c, and 11d constitute four sets of magnetic material accommodation portions 11. The size of each of the magnetic material accommodation concave portions 11a, 11b, 11c and 11d is formed to be slightly larger than that of the magnetic plates 8a, 8b, 8c and 8d. The gaps between the adjacent magnetic material housing portions 11 and the gaps between the adjacent magnetic material housing concave portions 11a, 11b, 11c, and 11d are formed to have the same intervals S1.

Then, when the magnetic plates 8a, 8b, 8c, 8d are respectively accommodated in the magnetic material accommodation recesses 11a, 11b, 11c, 11d, as shown in FIG. 3B, the magnetic plates 8a, 8b, 8b, 8c 8c and 8d are inserted into the magnetic material accommodation concave portions 11a, 11b, 11c and 11d so as to be brought close to the center of the magnetic material accommodation portion 11. The magnetic plates 8a, 8b, 8c, 8d inserted into the magnetic material accommodation recesses 11a, 11b, 11c, 11d are temporarily fixed, for example, by an adhesive or the like.
As a result, each gap 9B between adjacent magnetic plate groups 8 has a space S2, and each gap 9A between adjacent magnetic plates 8a, 8b, 8c and 8d has a space S1, the magnetic plates 8a and 8b. , 8c, 8d are accommodated in the magnetic material accommodation recesses 11a, 11b, 11c, 11d.
The magnetic plate case 10 is attached so as to cover the opening of the coil case 3 so that the plurality of magnetic plates 8 a, 8 b, 8 c, 8 d cover the upper side of the capacitor module 7.

  Therefore, according to the coil unit 1 of the present embodiment, the respective magnetic material accommodation recesses 11a, 11b, of the magnetic plate case 10 for accommodating the plurality of magnetic plates 8a, 8b, 8c, 8d in a predetermined position. The magnetic plates 8a, 8b, 8c, 8d can be easily accommodated by forming the size of 11c, 11d slightly larger than the magnetic plates 8a, 8b, 8c, 8d. And magnetic board 8a, 8b, 8c, 8d accommodated in each magnetic material accommodation concave part 11a, 11b, 11c, 11d overlaps with capacitor module 7 (refer to the imaginary line in (b) of Drawing 3) by plane view. The shielding effect on the element 73 is maintained by arranging the interval S1 of the gap 9A between the magnetic plates 8a, 8b, 8c and 8d in the position to be narrower than the interval S2 of the gap 9B in the non-overlapping position. Can. Therefore, it is possible to further reduce the manufacturing cost by lowering the assembly accuracy when the magnetic plates 8a, 8b, 8c, 8d are accommodated in the magnetic material accommodation concave portions 11a, 11b, 11c, 11d of the magnetic plate case 10. In addition, the reduced assembly accuracy facilitates, for example, automatic assembly.

  Therefore, according to the coil unit 1 of the present embodiment, by forming the magnetic material that covers the capacitor module 7 with the plurality of divided magnetic plates 8a, 8b, 8c, 8d, the non-contact power feeding can be performed at low cost. Coil unit 1 can be provided.

  The present invention is not limited to the embodiments described above, and appropriate modifications, improvements, etc. are possible. In addition, the material, shape, size, number, arrangement location, and the like of each component in the embodiment described above are arbitrary and not limited as long as the present invention can be achieved.

Here, the features of the embodiments of the non-contact power feeding coil unit according to the present invention described above will be briefly summarized and listed below.
[1] A coil case (3) for housing the coil in a housing space having a coil (5), a bottom wall (2) and a peripheral wall (4) in a noncontact power feeding system and having an open top, A coil unit comprising: an electric component (capacitor module 7) disposed at a winding center of the coil wound on the bottom wall along a peripheral wall; and a magnetic material covering the electric component. ,
The magnetic material is constituted by a plurality of magnetic plates (8a, 8b, 8c, 8d) arranged to be divided at a position not overlapping the element (73) mounted on the electric component. Coil unit (1).
[2] A magnetic plate case (10) for accommodating the plurality of magnetic plates arranged in a predetermined position is provided, and gaps (9A, 9B) between the adjacent magnetic plates are seen in plan view of the electric component So as to make the gap (9A) at a position overlapping with the electric component in a plan view narrower than the gap (9B) at a position not overlapping with each other, each accommodating portion of the magnetic plate case (magnetic material accommodation recess 11a, 11b, 11c , 11d), wherein each of the magnetic plates is accommodated.

1 coil unit 2 bottom wall 3 coil case 4 peripheral wall 5 coil 7 capacitor module (electrical part)
8a, 8b, 8c, 8d Magnetic plate 9A, 9B Gap 10 Magnetic plate case 11a, 11b, 11c, 11d Magnetic material accommodation recess (housing portion)
73 elements

Claims (2)

A coil in a non-contact power feeding system, a coil case having a bottom wall and a circumferential wall, and a coil case for accommodating the coil in a housing space opened at the top, and the coil wound on the bottom wall along the circumferential wall A coil unit comprising: an electrical component disposed at a winding center of the coil; and a magnetic material covering the electrical component,
A coil unit comprising: a plurality of magnetic plates arranged to be divided at a position not overlapping the element mounted on the electrical component.   The electric component is provided with a magnetic plate case for accommodating the plurality of magnetic plates arranged in a predetermined position, and the gaps between the adjacent magnetic plates are not overlapped with the electric component in a plan view. The coil unit according to claim 1, wherein the magnetic plates are accommodated in the accommodating portions of the magnetic plate case so that a gap at a position overlapping in a plan view becomes narrower.

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