JP2006303382A - Method for manufacturing non-contact power supply module - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a method for easily manufacturing a high quality non-contact power supply module. <P>SOLUTION: This method for manufacturing a non-contact power supply module comprises a sheet sandwiching process for sandwiching the both sides of a substrate 52 on which a coil 1 and a core 55, a circuit 58 and a lead wire 54 are mounted by a pair of cover sheets 51 formed so as to be made long outward from a substrate 52 at the deriving side of a lead wire 54; a resin packing process for packing resin 70 between the pair of cover sheets 51 from the deriving side of the lead wire 54, and for sealing the coil 1, the core 55, and the circuit 58; and a sheet cutting process for cutting the section formed so as to be made long outward from the substrate 52 of the pair of cover sheets 51. <P>COPYRIGHT: (C)2007,JPO&INPIT

Description

  The present application belongs to a technical field of a manufacturing method of a non-contact power supply module that supplies or receives power by non-contact electromagnetic induction, and particularly, a technical field of a manufacturing method of a non-contact power supply module that is manufactured by molding a non-contact power supply module. Belonging to.

  In recent years, research and development on various display devices have been actively performed. As one of them, an organic EL (Electro Luminescence) display device has been developed to a practical stage. This organic EL display device has features such as high brightness, high definition, high-speed response, and a high viewing angle, and is expected as a next-generation display device.

  In addition, the organic EL display device has a feature that it can be configured as a display device that is thin and bendable like paper due to its structure. By constructing the posting itself with an organic EL display device, it is also possible to realize the posting in which the visual effect as the posting is greatly improved by light emission.

  Here, when the posting is constituted by the organic EL display device as described above, it is naturally necessary to supply electric power for driving the organic EL display device as the posting at the time of the posting. . And, considering that it is necessary to be able to attach to and detach from the posting place such as a wall as a characteristic of the posting thing, it is considered that the power supply by the conventional method is the above posting place and the posting thing. A configuration is conceivable in which an electrical contact is provided and electric power is supplied to the posting from an electric power supply source provided at the posting location.

  However, in the case of power supply through such an electrical contact, the electrical contact degree is reduced by repeating the attachment and detachment many times (that is, the resistance value at the contact increases), thereby supplying power. Has the problem of becoming inefficient. In addition, in the case of electrical contacts, the metal part is exposed to the outside air, and therefore there is a problem that it cannot be used for power supply to outdoor postings, including problems such as corrosion or rust and safety.

  Therefore, in view of such problems, as a power feeding method for the above-mentioned light emitting type posting, a non-contact type power feeding method using an electromagnetic induction action is examined instead of a conventional method using an electrical contact. Yes. In other words, the receiving coil of one non-contact power supply module is provided on the back surface of the organic EL display device as a posting, and the other non-contacting portion is located at a position where the receiving coil is within a range such as a wall where the posting is posted. A power supply coil of the contact power supply module is provided, and an electric current is passed through the power supply coil to cause an induction current in a power reception coil at a position facing the power supply coil by electromagnetic induction, and the induction current is connected to the power reception coil. The organic EL display device as a posted object is driven (or a storage battery for driving the organic EL display device is charged).

  As a first method for manufacturing such a contactless power supply module, there is a method in which a substrate on which a coil, a core, a circuit, and the like are mounted is inserted and fixed in a polycarbonate case, and both are welded by ultrasonic waves.

  In addition, as a second manufacturing method, there is a method in which a polyamide resin is filled around a substrate on which a coil, a core, a circuit, and the like are mounted, and then cured by cooling.

  Furthermore, as a third manufacturing method, there is a method in which an epoxy resin is filled around a substrate on which a coil, a core, a circuit, and the like are mounted, and is molded.

  And as a 4th manufacturing method, there exists the method of filling the periphery of the board | substrate with which the coil, the core, the circuit, etc. were mounted, and molding.

  However, in the first method for manufacturing a non-contact power supply module described above, a polycarbonate case needs to be molded with high accuracy, and thus there is a problem that the manufacture of a mold is expensive.

  Further, in the second manufacturing method, since the polyamide resin is filled into the substrate and molded, the polyamide resin has low fluidity due to the nature of the polyamide resin, and the adhesion to the core is poor, so that the core cannot be securely adhered. There is a case.

  Further, in the third manufacturing method, since the epoxy resin is filled into the substrate and molded, the epoxy resin is cured at a high temperature, which causes a problem of deteriorating the characteristics of the electronic components of the mounted circuit.

  In the fourth manufacturing method, since the substrate is filled with urethane resin and molded, the property of the urethane resin is high in adhesiveness after curing, is difficult to handle, and is not suitable for actual use. There's a problem.

  The present invention has been made in view of the above circumstances, and the object of the present invention is to provide a method for manufacturing a non-contact power supply module that is easy to manufacture and can manufacture a high-quality non-contact power supply module. It is to provide.

  In order to solve the above-described problem, a method of manufacturing a non-contact power supply module according to claim 1 includes a coil and a core that supply or receive power by non-contact electromagnetic induction, and supply or receive power to the coil. A sheet sandwiching step of sandwiching a circuit and a lead wire connected to the circuit from both sides of the substrate by a pair of cover sheets formed so that the lead-out side of the lead is extended outward from the substrate; A resin filling step for sealing the coil, the core, and the circuit mounted on the substrate by filling a resin between the pair of cover sheets from the lead-out side, and forming the pair of cover sheets long from the substrate to the outside And a sheet cutting step for cutting the cut portion.

  The method for manufacturing a non-contact power supply module according to claim 2 is characterized in that, in the method for manufacturing a non-contact power supply module according to claim 1, the pair of cover sheets are formed in a flat plate shape. To do.

  Furthermore, the manufacturing method of the non-contact power supply module according to claim 3 is the manufacturing method of the non-contact power supply module according to claim 1 or 2, wherein the pair of cover sheets are previously formed with cut lines at the portions to be cut. It is characterized by being.

  And the manufacturing method of the non-contact electric power feeding module of Claim 4 is a manufacturing method of the non-contact electric power feeding module as described in any one of Claims 1 thru | or 3. WHEREIN: A pair of said cover sheet is a product made from glass epoxy, or It is characterized by being made of any material made of polycarbonate.

  The method for manufacturing a non-contact power supply module according to claim 5 is the method for manufacturing a non-contact power supply module according to claim 1, wherein the resin to be filled is a urethane resin.

  According to the first aspect of the present invention, the sheet sandwiching is performed by the pair of cover sheets formed so that the lead wire lead-out side is longer than the board from both sides of the board on which the coil, the core, the circuit, and the lead wire are mounted. Forming from the lead-out side of the lead wire and filling the resin between the pair of cover sheets to seal the coil, core and circuit mounted on the substrate, and forming the pair of cover sheets long from the substrate to the outside By providing a sheet cutting step for cutting the cut portion, it is easy to manufacture and a high quality non-contact power supply module can be manufactured.

  That is, since the coil and the core, the circuit, and the lead wire are sandwiched between the pair of cover sheets from both sides of the substrate, the non-contact power supply module can be thinned. In addition, since the resin is filled from the portion of the pair of cover sheets that is long outward from the substrate, the mold can be easily manufactured and the resin can be filled easily. Furthermore, since the part formed long outside from the substrate of the pair of cover sheets is cut, the pair of cover sheets can be easily formed in a desired dimension.

  According to the second aspect of the present invention, since the pair of cover sheets are formed in a flat plate shape, the interval between the power supply and power receiving non-contact power supply modules can be set accurately. As a result, power transmission efficiency can be increased.

  According to the invention according to claim 3, since the pair of cover sheets has a cut line formed in advance in the part to be cut, the part formed long outside from the substrate can be easily cut from the cut line, The sheet cutting operation can be simplified.

  According to the invention according to claim 4, since the pair of cover sheets is made of either glass epoxy or polycarbonate, the pair of cover sheets has a desirable rigidity, and is a non-contact power supply module for power supply and power reception. Can be set accurately. As a result, power transmission efficiency can be increased.

  According to the invention which concerns on Claim 5, since urethane resin was used for resin to fill, wraparound of resin becomes favorable and it can mold a coil, a core, and a circuit reliably.

  Next, the best mode for carrying out the present invention will be described with reference to FIGS. The embodiment described below is a non-contact power supply module that supplies power for driving an organic EL display (hereinafter simply referred to as a display) used as a poster from the wall side on which the display is posted. It is embodiment at the time of applying this invention with respect to.

  FIG. 1 is an external perspective view showing an outline of a contactless power transmission device including a contactless power supply module according to an embodiment, FIG. 2 is a block diagram showing the configuration of the contactless power transmission device, and FIG. 3A shows the structure of the non-contact power supply module, FIG. 3A is a diagram showing the mounting state of the pot-type core, FIG. 3B is a cross-sectional view showing the non-contact power supply module on the power supply side, and FIG. 4 is a plan view showing the non-contact power supply module on the side, FIG. 4 shows the non-contact power supply module on the power receiving side, FIG. 4 (a) is a cross-sectional view showing the non-contact power feeding module on the power receiving side, and FIG. FIG. 5 is a diagram showing a manufacturing process of the non-contact power feeding module on the power feeding side, and FIG. 6 is a diagram showing a specific example of the resin filling process.

  As shown in FIG. 1, the contactless power transmission device S according to the present embodiment includes a power receiving coil 10 including a power receiving core and a power receiving unit 20, a power receiving side contactless power supply module A, a driving unit 30, and a display. 40 and a posting side P attached to a position where the non-contact power feeding module A on the power receiving side is disposed in the posting range PS of the wall W on which the posting P is posted. And a contact power supply module SP.

  The non-contact power supply module SP on the power supply side is configured to include a power supply coil 1 including a power supply core, a power supply unit 2, and a detection unit 3. In the case of posting, the posting P is posted so that the feeding coil 1 and the receiving coil 10 face each other in parallel and are close to a distance of about 2 millimeters, for example.

  Next, a specific configuration will be described with reference to FIG.

  As shown in FIG. 2, the non-contact power supply module SP on the power supply side according to the present embodiment includes a male plug 100 inserted into a female plug (wall outlet) (not shown) to which, for example, AC power of 100 volts is supplied. The power supply unit B and the power supply coil 1 including the power supply unit 2, the detection unit 3, and the power supply core constituting the non-contact power supply module SP on the power supply side.

In this configuration, when the alternating current S ₁₀₀ is supplied from the female plug to the male plug 100, the power supply unit B that is actually configured as a so-called AC adapter or the like converts the alternating current S ₁₀₀ into, for example, a direct current. The power is converted to a power supply current of 12 volts and output to the power feeding unit 2 as a power supply signal Sb.

  On the other hand, the detection unit 3 configured by a photo reflector or the like, which will be described later, optically determines whether or not the posting P is present (posted) at a position where the feeding coil 1 and the receiving coil 10 face each other in parallel. When the posting P is detected automatically, a detection signal Sd indicating that the posting P is at the position is generated and output to the power feeding unit 2.

  Thereby, the power supply unit 2 converts the power supply signal Sb into a pulsed power supply signal Ss having a preset frequency (for example, 20 kilohertz), and only when the detection signal Sd is output from the detection unit 3. In other words, the feeding signal Ss is sent to the feeding coil 1 only when the detection unit 3 confirms that the posting P is posted at the predetermined position (a position where the feeding core and the receiving core face each other in parallel). Supply.

  On the other hand, the posting P according to the present embodiment includes the power receiving coil 10 including the power receiving core, the power receiving side non-contact power feeding module A including the power receiving unit 20, the driving unit 30, and the display 40. The power receiving unit 20 includes a power feeding circuit including a group of power receiving electronic components, and receives the induced electromotive force generated in the power receiving coil 10.

  In this configuration, the power receiving coil 10 is in a position facing the power feeding coil 1 in the vicinity of and in parallel to the power feeding coil 1 in a state in which the posting P is posted at the predetermined position. Composed. In this state, when the power feeding signal Ss is supplied to the power feeding coil 1, an induced electromotive force corresponding to the magnitude is generated in the power receiving coil 10, thereby receiving power from the power receiving coil 10 to the power receiving unit 20. A signal Sps is output.

  Next, the power reception unit 20 to which the power reception signal Sps is input processes the current and voltage in the power reception signal Sps and outputs the processed current and voltage to the drive unit 30 as the drive signal Srb.

  As a result, the drive unit 30 generates a drive signal Sd for driving the display 40 based on the drive signal Srb, and outputs the drive signal Sd to the display 40 to display on the display 40.

  Next, specific structures of the non-contact power supply module SP on the power supply side and the non-contact power supply module A on the power reception side according to the present embodiment will be described with reference to FIGS. 3 and 4. First, the non-contact power supply module SP on the power supply side will be described.

  As shown in FIG. 3, the non-contact power supply module SP on the power supply side is entirely formed in a rectangular thin flat plate shape, and a lead wire 54 connected to the power supply unit B is led out at the end.

  As shown in FIG. 3B, the non-contact power supply module SP on the power supply side includes a pair of cover sheets 51 made of glass epoxy or polycarbonate, and a base substrate 52 arranged between the cover sheets 51, Positioning spacers 53 and 54 for pot-type cores, which will be described later, arranged on one side in the longitudinal direction of the base substrate 52, and a pot-type core 55 arranged on the spacer 53 at a position defined by the spacer 54, The feeding coil 1 mounted in the groove portion 56 formed in the pot-type core 55 is connected to the feeding coil 1 via a wire such as a lead wire 61 and disposed on the other side in the longitudinal direction of the base substrate 52. Connected to the power supply circuit 58 and the power supply circuit 58 (corresponding to the power supply unit 2). And it is configured to include a lead wire 54. Further, a urethane resin 70 is filled between the pair of cover sheets 51 in order to position and fix each component.

  The pair of cover sheets 51 is formed into a rectangular flat plate with a smooth surface by glass epoxy or polycarbonate produced by laminating and pressing a glass nonwoven fabric into epoxy resin. In addition, the pair of cover sheets 51 is formed so that the lead-out side of the lead wire 54 is elongated to the outside of the end portion of the base substrate 52 as the cut portion 51 a, and at a portion corresponding to the end portion of the base substrate 52 or the vicinity of the end portion. A cut line 51b is formed in advance. As the base substrate 52, an FPC (Flexible Printed Circuit) substrate or the like is used.

  The spacers 53 and 54 are made of glass epoxy and adjust the height of the pot-type core 55 in the non-contact power supply module SP on the power supply side and adjust the position where the pot-type core 55 is arranged. Is. That is, the positions of the pot-type core 55 in the non-contact power supply module SP on the power supply side are defined by the spacers 53 and 54.

  As shown in FIG. 3C, the pot-type core 55 is formed with an annular groove 56a for engaging with the feeding coil formed in the same shape as the annular feeding coil 1, as well as a lead wire 54 and Grooves 56b and 56c for attaching the convex body 62 to be formed are formed. The grooves 56a to 56c are in communication with each other, and the end of the groove 56c for the convex body 62 is in communication with the outside. Further, the pot-type core 55 is formed with an air vent groove 57 so that the resin can easily turn when being molded. This air vent groove 57 is in a direction perpendicular to the line connecting the groove 56b for attaching the lead wire 54 and the groove 56c for attaching the convex body 62, one of which is for attaching the feeding coil 1 It is formed extending from the side body of the pot-type core 55 so as to communicate with a part of the groove 56a and the other with the outside.

  The pot-type core 55 has the same area as the protruding portion inside the feeding coil engaging groove 56a and the protruding portion outside the feeding coil engaging groove 56a, or the protruding portion outside the groove 56a. Is designed to be equal to or larger than the area of the protruding portion inside the groove 56a. If comprised in this way, even if it forms groove | channel 56b, 56c, 57, the fall of transmission efficiency, such as leakage magnetic flux by groove | channel 56b, 56c, 57, can be prevented.

  The feeding coil 1 is connected to an annular coil body 60 in which a plurality of coils are wound in a planar shape, a lead wire 61 connected to one end of the coil body 60 and connected to a feeding circuit 58, and the other end of the coil body 60. And a convex body 62 that functions as a knob of the coil body 60. The feeding coil 1 is for engaging the feeding coil formed on the pot-type core 55 without touching the coil body 60 by picking the convex body 62 with a finger and engaging it with the groove 56a for feeding coil engagement. The coil body 60 can be easily positioned and attached to the groove 56a.

  Next, the structure of the non-contact power feeding module A on the power receiving side will be described with reference to FIG. Detailed description of the same members as those of the non-contact power supply module SP on the power supply side is omitted.

  As shown in FIG. 4, the non-contact power feeding module A on the power receiving side is formed in a rectangular thin flat plate as a whole, and lead wires 84 connected to an external output terminal such as a display panel are led out at the end. Yes.

  As shown in FIG. 4A, the power-receiving-side non-contact power supply module A includes a pair of cover sheets 81 made of glass epoxy or polycarbonate, a base substrate 82 disposed between the cover sheets 81, Positioning spacers 83 and 84 for a pot-type core 85 (described later) arranged on one side in the longitudinal direction of the base substrate 82, and a pot-type core 85 arranged on the spacer 83 at a position defined by the spacer 84 The power receiving coil 10 mounted in the groove 86 formed in the pot-type core 85 is connected to the power receiving coil 10 via a wire such as a lead wire 91 and disposed on the other side in the longitudinal direction of the base substrate 82. The power receiving circuit 88 including a group of electronic components for power feeding and the power receiving circuit 88 (corresponding to the power receiving unit 2) are connected to the power receiving circuit 88 via the drive unit 30. A lead wire 84 to be connected to an external output terminal such as Isupurei 40, it is configured to include a. Further, a urethane resin 95 is filled between the pair of cover sheets 81 in order to position and fix each component.

  The pair of cover sheets 81 is formed into a rectangular flat plate with a smooth surface by glass epoxy or polycarbonate made by laminating and pressing a glass nonwoven fabric into an epoxy resin in the same manner as the non-contact power supply module SP on the power supply side. . Further, the pair of cover sheets 81 is formed such that the lead-out side of the lead wire 91 is elongated to the outside of the end portion of the base substrate 82 as the cut portion 81 a, and the portion corresponding to the end portion or the vicinity of the end portion of the base substrate 82 is formed. A cut line 81b is formed in advance.

  As shown in FIG. 4B, the pot-type core 85 has an annular groove 86a for engaging the receiving coil formed in the same shape as the annular receiving coil 10, as well as a lead wire 91 and a later-described core. Grooves 86b and 86c for attaching the convex body 92 are formed. The grooves 86a to 86c are in communication with each other, and one end of the groove 86c for the convex body 92 is in communication with the outside. Further, the pot-type core 85 is formed with an air vent groove 87 so that the resin can easily turn when being molded. The air vent groove 87 is in a direction perpendicular to a line connecting the groove 86b for attaching the lead wire 84 and the groove 86c for attaching the convex body 92, and one of them is for attaching the power receiving coil 10. It is formed extending from the side body of the pot type core 85 so as to communicate with a part of the groove 86a and the other with the outside.

  The power receiving coil 10 is connected to an annular coil main body 90 in which a plurality of coils are wound in a planar shape, a lead wire 91 connected to one end of the coil main body 90 and connected to the power receiving circuit 88, and the other end of the coil main body 90. And a convex body 92 that functions as a knob of the coil body 90.

  Next, a method for manufacturing the non-contact power supply module SP on the power supply side in the present embodiment will be described based on FIG. Note that, by this manufacturing method, the non-contact power supply module A on the power receiving side is manufactured in the same manner as the non-contact power supply module SP on the power supply side.

  First, in the sheet sandwiching step, a pair of cover sheets 51 is prepared, and the base substrate 52 is attached on one cover sheet 51 with a double-sided tape or the like so that the cut portion 51a does not overlap on the lead wire 54 lead-out side. The spacers 53 and 54 for positioning the pot-type core 55 on one side in the longitudinal direction on the base substrate 52 are attached with double-sided tape or the like, and the pot-type core 55 is attached to the spacer 53 with double-sided tape or the like. Note that a power feeding circuit 58 is disposed in advance on the other side in the longitudinal direction of the base substrate 52. Further, the feeding coil 1 is attached to the groove portion 56 formed in the pot-type core 55 with a double-sided tape or the like, and the upper portion of the groove portion 56 is closed on the upper surface of the pot-type core 55, and the portion to be cut is provided on the lead wire 54 lead-out side The other cover sheet 51 is attached with double-sided tape or the like so that 51a is formed, and a power supply unit U that functions as a non-contact power supply module on the power supply side is manufactured (see FIG. 5A).

  Here, since the pair of cover sheets 51 are sandwiched from both sides of the base substrate 52 on which the feeding coil 1, the pot-type core 55, and the feeding circuit 58 are mounted, the non-contact feeding module SP on the feeding side can be thinned. Can do.

  Next, in the drying process, the power supply unit U is inserted into the mold 72 that has been preheated and dried with the lead wires 54 connected to the power supply unit B being led out (see FIG. 5A).

  Next, in the resin filling step, the urethane resin 70 is injected at normal pressure between the pair of cover sheets 51 from the lead wire 54 lead-out side in the mold 72 and waits until the urethane resin 70 is cured (FIG. 5). (See (b)).

  Here, the pair of cover sheets 51 are formed so that the lead-out side of the lead wire 54 is elongated to the outside of the end portion of the base substrate 52 as the cut portion 51a. While it becomes easy to inject the urethane resin 70 into the sheet 51, it can be spread evenly to every corner. On the other hand, when the pair of cover sheets 51 are formed to the same length as the base substrate 52, it is difficult to inject the urethane resin 70, and a portion where the urethane resin 70 does not reach the lead wire 54 is generated. There is.

  Next, in the mold release step, the urethane resin 70 is taken out from the mold 72 after curing (see FIG. 5C).

  Further, in the molding / finishing process as the sheet cutting process, the pair of cover sheets 51 are formed in a predetermined shape by cutting the cut portions 51a of the pair of cover sheets 51 from the cut lines 51b, and the non-feeding side The contact power supply module SP (or the non-contact power supply module A on the power receiving side) is manufactured (see FIG. 5D). Here, since the cut lines 51b are formed in the pair of cover sheets 51 in advance, the cut portions 51a formed long outward from the base substrate 52 of the pair of cover sheets 51 are cut. The cover sheet 51 can be easily cut into a desired size and shape.

  In this way, since the non-contact power supply module SP on the power supply side as shown in FIG. 3B can be manufactured by a simple process, the non-contact power supply module on the power supply side that can ensure a certain level of reliability without cost. SP can be manufactured.

  When the urethane resin 70 is injected between the pair of cover sheets 51, the urethane resin 70 is in a state where the mold 72 is inclined by about 30 degrees as shown in FIG. 6 (see FIG. 6A), and the dropper is placed. 73 or the like. Specifically, the urethane resin 70 is slowly injected from the gap between the power supply unit U and the mold 72 so that the urethane resin 70 wraps around the entire lower part of the power supply unit U (see FIG. 6B). Then, when the urethane resin 70 wraps around the lower part of the power supply unit U, the mold 72 is erected to inject the urethane resin 70 up to the upper surface of the mold 72 (the end of the base substrate 52) (FIG. 6C). reference).

  If comprised in this way, the urethane resin 70 makes the urethane resin 70 wrap around the groove | channel 56a for electric power feeding coils, and the groove | channel 56c for convex bodies through the groove | channel 56b formed in the pot type core 55 and communicating with the outside. Therefore, the urethane resin 70 can be completely filled in all the grooves of the pot-type core 55.

  Here, as described above, the pair of cover sheets 51 is formed so that the lead-out side of the lead wire 54 is formed as a part to be cut 51 a long outside the end of the base substrate 52. The urethane resin 70 can be easily injected and can be distributed evenly to every corner.

  Further, when the air vent groove 57 is not formed in the pot-type core 55, the groove 56 b for the lead wire 61 that connects the power feeding coil 1 and the power feeding circuit 58 also serves as an inlet and an outlet for the urethane resin 70. Therefore, the urethane resin 70 does not rotate well to the power supply coil groove 56a and the convex body groove 56c, and insufficient filling occurs. Therefore, in the present embodiment, by forming the resin injection (air venting) groove 57 that communicates with the pot-type core 55 and communicates with the power feeding coil groove 56a, the power feeding coil groove 56a or convexity is formed. The urethane resin 71 is completely filled in the groove 56c for the body.

  As described above, according to the present embodiment, the power supply coil 1, the pot-type core 55, and the power supply circuit 58 are sandwiched between the pair of cover sheets 51 from both sides of the base substrate 52. The SP can be thinned. In addition, since the urethane resin 70 is filled from the part formed long outside the base substrate 52 of the pair of cover sheets 51, the mold can be easily manufactured and the urethane resin 70 can be filled easily. Furthermore, since the part formed long outside from the base substrate 52 of the pair of cover sheets 51 is cut, the pair of cover sheets 51 can be easily formed to have a desired dimension.

  Further, according to the present embodiment, since the pair of cover sheets 51 are formed in a flat plate shape, the interval between the non-contact power supply module SP for power supply and the non-contact power supply module A on the power receiving side is accurately set. be able to. As a result, power transmission efficiency can be increased.

  Further, according to the present embodiment, since the pair of cover sheets 51 has the cut lines 51b formed in advance at the portions to be cut, the portions formed long outward from the base substrate 52 are easily cut from the cut lines 51b. Therefore, the sheet cutting operation can be simplified.

  And according to this embodiment, a pair of cover sheet 51 becomes desirable rigidity, and the space | interval of the non-contact electric power feeding module SP for electric power feeding and the non-contact electric power feeding module A on the power receiving side can be set correctly. As a result, power transmission efficiency can be increased.

  Further, according to the present embodiment, since the urethane resin 70 is used as the resin to be filled, the wraparound of the resin becomes good, and the power feeding coil 1, the pot-type core 55, and the power feeding circuit 58 can be reliably molded.

  Furthermore, according to the present embodiment, since the air vent grooves 57 and 87 are formed in the pot-type cores 55 and 85 so that a part of the grooves 56a and 86a for the feeding and receiving coils and the outside communicate with each other. The urethane resins 70 and 95 easily turn around the grooves 56a and 86a formed in the pot-type cores 55 and 85 through the grooves 57 and 87. As a result, the urethane resins 70 and 85 do not rotate well, and the power feeding or power receiving coil grooves 56a and 86a do not become insufficiently filled, and the urethane resins 70 and 85 are not affected by the power feeding coil grooves 56a and 86a. All of the grooves formed in the pot-type cores 55 and 85 can be completely filled. Therefore, the feeding or receiving coils 1 and 10 and the pot-type cores 55 and 85 are structured to be fixed at predetermined positions of the non-contact power feeding modules SP and A on the power feeding side or the power receiving side, and contactless on the power feeding side or the power receiving side. By simply arranging the power supply modules SP and A so as to overlap each other, power can be supplied constantly and appropriately.

  Moreover, since it can be manufactured easily, there are great cost effects such as cost reduction.

  Furthermore, by forming a plurality of air vent grooves 57 and 87 in the pot-type cores 55 and 85, the urethane resins 70 and 85 are more quickly and completely formed in the pot-type cores 55 and 85. It becomes possible to fill the groove. Here, the formation of the air venting grooves 57 and 87 may cause a decrease in transmission efficiency due to the influence of leakage magnetic flux, etc., but the annular feeding coil grooves 56a and 86a in the pot type cores 55 and 85 may be considered. There is a problem if the area of the inner protruding portion is equal to the area of the outer protruding portion of the grooves 56a and 86a, or the area of the outer protruding portion is equal to or larger than the area of the inner protruding portion. Don't be.

  In this embodiment, the non-contact power supply module SP on the power supply side is mainly described. However, the non-contact power supply module A on the power reception side has substantially the same configuration as the non-contact power supply module SP on the power supply side. Therefore, the non-contact power feeding module A on the power receiving side also has the same effect as the non-contact power feeding module SP on the power feeding side.

  In the present embodiment, the power received from the non-contact power feeding module on the power feeding side is displayed on the display P, but the power may be used in any form.

1 is an external perspective view showing an outline of a contactless power transmission device including a contactless power supply module according to an embodiment. It is a block diagram which shows the structure of a non-contact-type electric power transmission apparatus. FIG. 3A shows a structure of the pot-type core mounted, FIG. 3B is a cross-sectional view showing the non-contact power supply module on the power supply side, and FIG. ) Is a plan view showing a contactless power supply module on the power supply side. FIG. 4A is a cross-sectional view showing a power receiving side non-contact power feeding module, and FIG. 4B is a plan view showing the power receiving side non-contact power feeding module. It is a figure which shows the manufacturing process of the non-contact electric power feeding module by the side of electric power feeding. It is a figure which shows the specific example of the filling process of resin.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 Feeding coil 10 Power receiving coil 51, 81 Cover sheet 51a Cut part 51b Cut line 52, 82 Base 53, 54 Spacer 54, 61, 84, 91 Lead wire 56, 86 Groove 55, 85 Pot type core 57, 87 Air vent Groove 58 Power feeding circuit 70, 95 Urethane resin 88 Power receiving circuit S Non-contact power transmission device SP Non-contact power feeding module on the power feeding side A Non-contact power feeding module on the power receiving side B Power supply unit

Claims (5)

The lead from the board from both sides of the board on which a coil and a core that supply or receive power by non-contact electromagnetic induction, a circuit that supplies or receives power to the coil, and a lead wire connected to the circuit are mounted. A sheet sandwiching step of sandwiching by a pair of cover sheets formed on the outer side of the lead-out side of the wire;
A resin filling step of sealing the coil, the core, and the circuit, which is filled with resin between the pair of cover sheets from the lead wire lead-out side and mounted on the substrate;
A sheet cutting step of cutting a portion formed long outside from the substrate of the pair of cover sheets;
The manufacturing method of the non-contact electric power feeding module characterized by providing. In the manufacturing method of the non-contact electric supply module according to claim 1,
The method of manufacturing a non-contact power supply module, wherein the pair of cover sheets are formed in a flat plate shape. In the manufacturing method of the non-contact electric power feeding module according to claim 1 or 2,
The pair of cover sheets have a cut line formed in advance at a portion to be cut, and a method for manufacturing a non-contact power supply module. In the manufacturing method of the non-contact electric supply module according to any one of claims 1 to 3,
The method of manufacturing a contactless power supply module, wherein the pair of cover sheets is made of glass epoxy or polycarbonate. In the manufacturing method of the non-contact electric supply module according to claim 1,
The method of manufacturing a contactless power supply module, wherein the resin to be filled is a urethane resin.

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