JP2020013810A - Non-contact power supply device, coil, and manufacturing method of coil - Google Patents

Abstract

PROBLEM TO BE SOLVED: To obtain a specified performance and to maintain a coil shape with good handleability without using an interval holding member. SOLUTION: The coil 20 of the present invention is a coil 20 formed by winding an electric wire a plurality of times, and the electric wires of the Nth, (N + 1), and (N + 2) windings are separated from each other from the beginning of winding. The corner section A1 (where N is an integer of 1 or more) arranged in a curved line, and the Nth winding wire and the (N + 2) winding wire every other winding on both sides of the corner section A1 in the winding direction. Is a parallel section in which is wired in parallel at regular intervals, and the first (N + 1) winding wire meanders within the interval and is separated from other parallel winding wires in the parallel section. The first and second contact sections P1 and P2, which are arranged on both sides of the separation section P3 and the first separation section P3 and in which the wire of the first (N + 1) winding abuts on any of the wires of the parallel winding. Has a straight section A2 and has. [Selection diagram] Fig. 1

Description

  The present invention relates to a non-contact power supply device, a coil, and a method for manufacturing a coil.

  2. Description of the Related Art In recent years, the adoption of non-contact power supply for power supply systems for automatic guided vehicles and electric vehicles has been studied.

  The non-contact power supply technology includes, for example, a power transmission (primary side) planar coil (ground side coil) provided to be embedded in a road surface of a power supply station and a power reception (secondary side) provided at the bottom of an electric vehicle. This is a technique in which a flat coil (vehicle-side coil) is opposed at a fixed interval, for example, an interval of about several tens of cm, and wirelessly transmits electric power to supply power to an electric vehicle.

  In non-contact power feeding, high power transmission efficiency is required, and a coil used for the power transmission is required to have low loss. Therefore, it is necessary to reduce the copper loss, that is, the AC resistance of the coil used for the non-contact power supply.

  For planar coils used for non-contact power supply for electric vehicles, drive frequency, minimum transmission efficiency including coil displacement, allowable range of displacement between ground side coil and vehicle side coil, etc. are being standardized. Companies will compete to develop better products.

  When actually installing the coil in a power supply station or vehicle, the outer shape, inner diameter, number of turns, etc. of the coil may also be specified. It is required to create a coil that also maintains the strength for holding.

  The following two factors can be considered as factors affecting the AC resistance of the coil. The first factor is a DC resistance depending on the conductor cross-sectional area of the wire for winding, and the second factor is a loss due to a proximity effect and a skin effect which change depending on a frequency, a twist configuration of the wire, a coil form, and the like.

  In particular, in the non-contact power supply, since it is used in a high-frequency band on the order of kHz, the influence of the second factor becomes large. In order to reduce the influence of the second factor, a coil wound with a gap between windings (hereinafter referred to as a “gap wound coil”) is suitable as a coil using a litz wire as a wire material. .

  In view of the above circumstances, a conventional coil used for non-contact power feeding is configured such that a litz wire (insulated conductor) formed by twisting a plurality of thin enamel wires is wound spirally in a plane and with a gap between the windings. Formed.

  By the way, if a gap is provided between the windings, at the manufacturing site, it is necessary to transport the product as a coil, transfer the coil during manufacturing, and suppress the fluctuation of the coil inductance. In addition, it is necessary to consider the manufacturability in the step of winding the wire into a coil shape (easiness of winding the wire by an automatic winding machine) and the subsequent shape retention and handling.

  The conventional technique of providing a gap between the windings is to prepare a support substrate in which a groove provided with a gap is formed in a spiral shape, and manually insert an electric wire into the groove of the support substrate, a `` groove fitting structure '', or There is a technique such as a “spacer structure” in which a spacer is provided between windings and the winding is wound (for example, see Patent Document 1).

  In the case of a coil with a “groove fitting structure”, in addition to the cost of the support substrate, the cost of manufacturing is increased due to the preparation of the support substrate, and the size of the coil unit is also increased, leading to an increase in transportation costs. There is. In addition, since a coil having a "spacer structure" also requires a spacing member called a spacer, there is a problem that the member cost and manufacturing cost increase substantially in the same manner as in the "groove fitting structure".

JP 2008-60432 A

  In the case of a conventional coil in which a current-carrying wire is wound in a plane as described above, a supporting substrate having a groove formed is prepared for maintaining the shape of the coil, or a spacer is interposed between the windings to handle while maintaining a gap. Therefore, there is a problem that the cost of parts must be ensured, the cost of parts such as a spacer and a substrate is increased, and the work reduces production efficiency.

  Therefore, the present invention has been made to solve the above-described problems, and has a specified performance, and has a coil shape with good handling properties without using a spacing member such as a spacer or tape or a support substrate having a groove. It is an object of the present invention to provide a non-contact power supply device capable of holding a coil, a coil, and a method for manufacturing the coil.

  In order to achieve the above object, a coil according to one embodiment of the present invention is a coil formed by winding an electric wire a plurality of times, and includes the Nth, (N + 1) th, and (N + 2) th turns from the beginning of winding. (Where N is an integer equal to or greater than 1), and every other winding (the N-th wire and the ( (N + 2) -th winding) is a parallel section in which the (N + 1) -th winding is meandering within the interval and parallel to another parallel winding in the parallel section. A first separation section separated from the electric wire, and first and second abutments disposed on both sides of the first separation section, wherein the (N + 1) th wire is in contact with one of the parallel winding wires. And a straight section having a section.

  A non-contact power supply device according to one embodiment of the present invention includes a metal or resin substrate, a magnetic core plate disposed on the substrate, and the coil disposed on the magnetic core plate.

  A method for manufacturing a coil according to one embodiment of the present invention is a method for manufacturing a coil in which a wire is wound a plurality of times to form a coil having a corner section and a straight section on both sides in a winding direction of the corner section, In the corner section, the Nth, (N + 1) th and (N + 2) th winding wires are separated from the beginning of the winding and arranged in a curved line, and in the straight section, every other winding is fixed at a constant interval. Arranging a parallel section that is wired in parallel with the first section, and a first separation section in which the (N + 1) -th winding electric wire meanders within the interval and separates from other parallel winding electric wires within the parallel section. In the straight section, and, on both sides of the first separated section in the straight section, first and second contact sections in which the (N + 1) th wire abuts on one of the parallel wires. And arranging. That.

  Advantageous Effects of Invention According to the present invention, it is possible to provide a non-contact power supply device, a coil, and a method for manufacturing a coil that are low in cost and have good manufacturing workability while obtaining specified performance.

FIG. 3 is a plan view of a spiral coil (coil having a square outer shape) according to the first embodiment of the present invention. The enlarged view which shows the principal part (corner section A1, the part of straight section A2) of the coil of FIG. FIG. 2 is a diagram showing separated sections (sections P3 and P4) of electric wires in the coil of FIG. 1. FIG. 4 is an enlarged view showing a straight line connecting the center positions of the radii R1 and R2 of the corners of the coil. The top view of the spiral coil (coil of a rectangular external shape) of 2nd Embodiment. FIG. 6 is an enlarged view showing a main part (a section of a corner section A1 and a straight section A2) of the coil of FIG. 5. FIG. 6 is a frequency-AC resistance characteristic diagram comparing the coil of FIG. 5 with a comparative example. The BB sectional view of Drawing 1 showing the non-contact electric supply using the coil of a 1st, 2nd embodiment.

Hereinafter, embodiments of the present invention will be described with reference to the drawings.
The non-contact power supply device is configured by arranging a primary-side non-contact power transmission device and a secondary-side non-contact power reception device in opposition to each other. The primary-side non-contact power transmission device, which supplies power, and the secondary-side non-contact power reception device, which receives power, have substantially the same coil elements, and in this case, This side will be described, but it goes without saying that the other side is also the same.

(1st Embodiment)
Hereinafter, the coil 20 according to the first embodiment of the present invention will be described with reference to FIGS. FIG. 1 is a plan view of a spiral coil (corner winding coil) according to a first embodiment of the present invention, and FIG. 2 is a main part (corner section A1, straight section A2, and some sections P1 to P4 of each section). FIG.

  As shown in FIGS. 1 and 2, the coil 20 of the first embodiment according to the present invention winds a single wire or a litz wire 22 as an insulated conductor from a position A0 on the innermost circumference in a winding direction C. For the first time, it is formed by spirally laying flatly (in a plane) so as to provide a corner section A1 where the electric wire is curved and arranged and a straight section A2 where the electric wire is arranged linearly every other turn. The (manufactured) coil has a substantially square shape (the corner section A1 is rounded).

  The straight section A2 is a parallel section in which the odd-numbered electric wires n1, n3, n5, n7, and n9 are arranged in parallel at regular intervals every other turn, and the even-numbered electric wires n2, n4, and n6. , N8 meander within the interval, and are arranged so as to abut and separate from the parallel wires n1, n3, n5, n7, n9.

In the straight section A2 (within the parallel section), even-numbered wires n2, n4, n6, and n8 are separated from other parallel odd-numbered wires n1, n3, n5, n7, and n9 at the center. A section P3, which is a first separated section, is arranged.
On both sides of the section P3, sections P1 and P2 where even-numbered electric wires n2, n4, n6, and n8 abut on any of the parallel odd-numbered electric wire lines n1, n3, n5, n7, and n9 are arranged. Have been. The section P1 arranged on the left side of the section P3 is referred to as a first contact section. A section arranged on the right side of the section P3 is referred to as a second contact section P2.

The section P1 is a section where the odd-numbered electric wire n1 abuts the even-numbered electric wire n2 on the outer peripheral side thereof, and the even-numbered electric wire n2 and the odd-numbered electric wire n3 on the outer peripheral side thereof are separated from each other. .
The section P2 is a section in which the odd-numbered electric wire n1 and the even-numbered electric wire n2 on the outer peripheral side thereof are separated from each other, and the even-numbered electric wire n2 and the odd-numbered electric wire n3 on the outer peripheral side thereof are in contact with each other.

If the number of turns of the electric wire is replaced with N and the Nth, (N + 1) th, and (N + 2) th turns from the beginning of the electric wire winding, the section P1 is the Nth electric wire n1 and the (N + 1) th turn. And the (N + 1) th wire n2 and the (N + 2) th wire n3 are separated from each other. Note that N is an integer of 1 or more.
The section P2 is a section where the electric wire n1 of the Nth winding and the electric wire n2 of the (N + 1) th winding are separated, and the electric wire n2 of the (N + 1) th winding and the electric wire n3 of the (N + 2) th winding are in contact with each other. is there.

  In the corner section A1, the electric wires n1, n2, n3,..., N7, n8, n9 of the respective windings are arranged in a curved shape with a distance. That is, the N-th, (N + 1) -th, (N + 2) -th, etc. electric wires are spaced apart and arranged in a curved shape.

  In the corner section A1, the radius (R1) of the arc (curve) drawn by the odd-numbered electric wires n1, n3, n5, n7, and n9 and the radius (arc) drawn by the even-numbered electric wires n2, n4, n6, and n8. R2 is, for example, 40.0 mm (referred to as R40), and the radii R1 and R2 are the same. Note that the radii R1 and R2 may be different from each other.

  A section P4 is arranged in the corner section A1. The section P4 starts from the contact between the (N + 1) -th wire (for example, the wire n2) and the N-th wire (for example, the wire n1) in the straight section A2 disposed in the front of the winding direction. This is a second separation section in which the (N + 1) -th wire (for example, the wire n2) and the (N + 2) -th wire (for example, the wire n3) are brought into contact with each other in a section P2 disposed earlier in the direction.

  In the corner section A1, the radius of the curved portion (arc portion) of the odd-numbered wires n1, n3, n5, n7, and n9 and the even-numbered wires n2, n4, n6, and n8 is determined. R1 and R2 are wound with the same diameter, and the adjacent electric wires (for example, the electric wire n1 and the electric wire n2, the electric wire n2 and the electric wire n3) are separated from each other, and the straight section A2 on both sides of the corner section A1 (before the corner section A1). Since the wires are in contact with each other in the section P1 and the section P2 before the corner section A1, they are referred to as "corner winding coils".

  For winding the coil 20, an automatic winding device using a mold (winding jig) having a spiral groove is used. The automatic winding device fixes the sending position of the litz wire 22, applies the litz wire 22 to the groove of the winding jig, rotates the winding jig planarly while feeding the litz wire 22, and inserts the litz wire into the groove. 22 is a device that is fitted in order.

  The coil 20 which is simply wound in a spiral shape in a plane is disintegrated at the time of taking out from the mold (winding jig) or at the time of transportation, so that the coil 20 of FIG. 1 fitted into the mold (winding jig) is used. The adhesive is sprayed in this state, the contact portions between the windings are adhered to each other, and the winding is left for a certain period of time until the adhesive is solidified, and then handled. The bonding of the contact portions may be performed by heating using, for example, a litz wire 22 wrapped with a heat-fusible fiber, and may be performed by using a self-fusing wire provided with a self-fusing layer on the outermost layer. Welding or solvent bonding may be used, or an acetate thread may be wound around the litz wire 22 and solvent bonded.

  In other words, the coil 20 is formed by winding the litz wire 22 while arranging it almost flat, and regularly forming a separation portion and a contact portion between the wires to form a spiral shape. It is bonded (fixed) with an adhesive, and a pair of crimp terminals 21 and 24 are connected to both ends of the litz wire 22. The crimp terminals 21 and 24 may be attached to both ends before or after bonding.

  The litz wire 22 is a wire group formed by twisting a plurality of enamel wires and forming a bundle. In this example, a litz wire 22 having a wire diameter of, for example, about 4.4 mm is used. As a current-carrying electric wire other than this example, for example, a conductor without insulation coating (a wire made of copper or aluminum), a self-fused wire having a self-fused layer provided on the outermost layer, or the like may be used. .

  The crimp terminal 21 is connected to one end on the inner side of the litz wire 22 and roughly includes a crimp portion and a fixing portion provided with a fixing hole. The crimping portion is formed of a cylindrical metal member, and the conductor portion from which the enamel coating of the litz wire 22 has been removed is inserted and crimped, whereby the wire and the metal portion are crimped and integrated, and the crimp terminal 21 is litz-bonded. Secure to line 22. The crimp terminal 24 is connected to one end outside the litz wire 22 and is the same as the crimp terminal 21.

  As shown in FIG. 2, the coil 20 is wound so as to provide four electric wire wiring sections P1 to P4 (hereinafter referred to as “sections P1 to P4”) P1 to P4 in one round of winding. A section P2, a section P3, and a section P1 are arranged in the straight section A2, and a section P4 is arranged in the corner section A1. In the direction of winding the electric wire from the straight section A2 to the corner section A1, the sections P1 to P4 are arranged so as to repeat in the order of the section P2, the section P3, the section P1, and the section P4.

  The section P1 (first contact section) includes the N-th wire from the start of winding (the wire n1 in the case of the first winding from the inside) and the (N + 1) -th wire (the second winding from the inside). In this case, the abutting portion where the wire n2 abuts, the (N + 1) th wire (the second wire n2 from the inside) and the (N + 2) th wire (the third wire from the inside) Is a section having a separated portion where the electric wire n3) is separated. N is an integer of 1 or more.

  In the section P2 (second contact section), the electric wire n1 that is the Nth electric wire and the electric wire n2 that is the (N + 1) th electric wire are separated from each other, and the electric wire that is the (N + 1) th electric wire. This is a section having a portion where the wire n2 and the wire n3, which is the (N + 2) th wire, are in contact.

  In the section P3 (first separated section), the electric wire n2, which is the (N + 1) th electric wire, is connected to the electric wire n1, which is the Nth electric wire, from the contact with the (N + 2) th electric wire n3. This is the section that switches to contact.

  In other words, in this section P3 (first separated section), the electric wires n2, n4, which are the electric wires of the second Nth winding, and the electric wires n3, n5, which are the electric wires of the (2N + 1) th winding outside the own wire. , Which are the electric wires n1, n3,..., Which are the (2N-1) th winding electric wires inside the own wire, cross the direction in which the electric wires n1, n3,.

  In the section P4 (the second separation section), the electric wire n2, which is the (N + 1) th electric wire in the straight section A2 disposed in the front of the winding direction, is positioned from the contact with the electric wire n1 in the winding direction. In the section P2 of the straight section A2, the section is switched to the contact with the electric wire n3 which is the (N + 2) -th winding electric wire.

  In other words, the section P4 (fourth section) is the (2N-1) th winding wire in the straight section A2 on the right-hand side of the drawing as the electric wires n2, n4. .. Traverses from the contact portion of a certain electric wire n1, n3, n5... In the direction in which the electric wire n3, n5. (Crossing) section.

  In the section P4, the even-numbered wire n2 (the second N-th wire) is switched so that the contact relationship between the wires of each winding is switched from the section P1 on the right side of the section P4 to the section P2 on the left side of the section P4. ) Is wound. That is, in this section P4, the even-numbered electric wire n2 is disposed so as to obliquely cross the gap between the odd-numbered electric wires n1 and n3.

  In other words, in the section P4, the even-numbered wires n2, n4,..., And the odd-numbered wires n1, n3, n5. Are arranged so as to cross and draw a curve with a radius R2 having a center position different from the center position. Note that the center position of the radius includes a center point for drawing the radius, a line connecting the center points, and the like.

  As shown in FIG. 2, the even-numbered electric wires n2... Of the section P4 include the first contact portion 31 of the first section P1 adjacent to one side (right side) of the section P4 and the other side (lower left) of the section P4. Side) is wound with a radius R2 having an arc center connecting the second contact portion 32 of the section P1 adjacent to the section P1.

  For example, the winding structure of the coil 20 will be described using the electric wires n1, n2, and n3 as an example. The coil 20 having a substantially square outer shape having a corner section A1 and a straight section A2 is divided into four sections P1 to P4. In the sections P1 and P2, the even-numbered electric wire n2 is meandered between the parallel odd-numbered electric wires n1 and n3 to abut and separate from each other.

  In the sections P3 and P4, the even-numbered wire n2 is obliquely crossed so as to switch the contact or separation of the wires n1, n2, and n3.

  In this manner, the wires having different windings are separated from each other in the section P3 of the straight section A2 and the section P4 of the corner section A1, and in the sections P1 and P2 therebetween, adjacent wires are brought into contact with each other at substantially constant intervals. By bonding the contact portions, the shape retention force as a coil can be improved.

  Note that, in this example, the number of turns of the entire coil is nine, but the present invention is applicable to other numbers of turns and winding methods. In this example, the total number of turns is an odd number, but may be an even number, and the number of turns itself may be increased or decreased.

  In this example, the litz wire 22 is spirally wound so that the outer shape is a quadrangle (when the outer shape is substantially square as in this example, the four corner sections A1 are rounded). In addition, the outer shape may be a polygonal shape such as a substantially triangular shape, a substantially pentagonal shape, a substantially hexagonal shape, a substantially octagonal shape, a substantially D shape, a substantially rectangular shape, or the like.

Hereinafter, a method of manufacturing the coil 20 shown in FIG. 1 will be described.
In this case, the coil 20 is formed by winding the litz wire 22 a plurality of times from the inner peripheral side toward the outer peripheral side with the innermost circumference as the first winding. At this time, the state of the wiring in the sections P1 to P4 is formed while the litz wire 22 is wound. In this embodiment, the winding of the electric wire is started from the innermost peripheral side, but may be started from the outermost peripheral side.

  In this case, when the litz wire 22 is wound along the winding direction C from the position A0, the first round (the first winding wire n1) excluding the corner section A1, the litz wire 22 is wound. Roll it straight without bending.

  In the second round, the electric wire n2 of the second winding enters the corner section A1 immediately after contacting the electric wire n1 of the first winding, so that the electric wire n2 is separated (branched) from the electric wire n1 in the corner section A1. To form a curve with a radius R2.

  In the section P2 of the straight section A2 ahead of the corner section A1, the electric wire n2 is wired so as to be in contact with the electric wire n3 wound around the next circumference.

  In the section P3 of the straight section A2, the electric wire n2 is bent away from the contact position with the electric wire n3 to be separated from the contact position with the electric wire n3 and wound obliquely toward the electric wire n1.

  Then, in the section P1, the electric wire n2 comes into contact with the electric wire n1 and is wound along the electric wire n1.

  Before entering the straight section A2, the electric wire n2 is separated from the electric wire n1 and wound around the electric wire n3 so as to draw an arc having a radius R2. Thus, the electric wire n2 is meandered for the remaining half of the circumference, and the second round is completed.

  Next, the third round (the third winding electric wire n3) winds the litz wire 22 in a straight line without bending the litz wire 22 along the same locus as the first round (the first winding electric wire n1). As a result, the third winding wire n3 comes into contact with the second winding wire n2 in the section P2.

  In this manner, the electric wires of the respective turns are arranged in a curved shape with a distance from each other in the corner section A1, and the odd-numbered electric wires n1, n3, n5, in the straight section A2 arranged on both sides in the winding direction of the corner section A1. n7 and n9 are arranged in parallel at regular intervals every other turn, and the even-numbered wires n2, n4, n6 and n8 within the intervals of the odd-numbered wires n1, n3, n5, n7 and n9. Meander, and are arranged so as to abut and separate from the parallel wirings n1, n3, n5, n7, n9.

  As described above, according to the non-contact power supply device of the first embodiment, the corner section A1 in which the electric wires of the respective turns are separated and curved in a curved shape, and the electric wires n1, n3 of the odd-numbered turns from the inner peripheral side. . Are wound in parallel to form a straight section A2 in which the even-numbered wires n2, n4... Meander so as to abut and separate from the odd-numbered wires n1, n3. As shown in FIG. 2, sections (switching sections P3 of the central portion of the straight section A2 and sections P4 of the corner sections A1) for switching to electric wires of other windings are provided at substantially constant intervals in the spiral coil, and these sections P3, By forming contact portions with other windings on both sides of P4 and bonding the respective contact portions, the shape holding force as a coil is improved, and without providing a spacer or a support substrate, between the electric wires. Carp with regular gaps The can now handling workability good non-contact power feeding device of low cost and coil production while obtaining the specified performance, it is possible to provide a manufacturing method of the coil and coil.

  Further, in the above embodiment, the radii R1 and R2 have the same diameter and the center positions are different. However, as shown in FIG. 4, a straight line connecting the center positions of the radius R1 of the odd-numbered electric wires n1, n3. Each position is different from the position of a straight line connecting the center positions of the radii R2 of the even-numbered electric wires n2, n4... (Specifically, the straight lines connecting the center positions of the radii R1 and R2 are parallel). A winding electric wire may be arranged. It is conceivable that the radii R1 and R2 are set to, for example, 40.0 mm (R40). By setting the radii R1 and R2 to be the same as described above, an effect is obtained that the electric wire can be easily wound by the automatic winding machine.

(2nd Embodiment)
Next, a second embodiment will be described with reference to FIGS. FIG. 6 is a plan view showing a coil (a pair of two-wire rectangular coils) of the second embodiment, and FIG. 7 is an enlarged view of a main part thereof. In the second embodiment, the same components as those in the first embodiment are denoted by the same reference numerals, and description thereof will be omitted.

  As shown in FIG. 5, although the coil 20 of the second embodiment has a corner section A1 and a straight section A2 on both sides thereof, the outer shape (vertical width and width) of the coil 20 is substantially rectangular different from that of the first embodiment. is there. The coil 20 is formed by winding a pair of litz wires 22a and 22b including an inner wire 22a and an outer wire 22b such that the outer shape is substantially rectangular (the corner section A1 is rounded). The electric wire itself is of a parallel type using two pairs of wires having the same diameter as that of the first embodiment.

If two wires each having a diameter of, for example, 4.4 mm are used, the cross-sectional area of the two wires is approximately 16.0 mm ² , which is twice the conductor cross-sectional area of one litz wire 22. , DC resistance is reduced by half, and loss and heat generation can be suppressed. It also contributes to making the magnetic field distribution of the coil more uniform.

  In the second embodiment, the section P1, the section P2, and the section P3 are arranged in the straight section A2, and the section P4 is arranged in the corner section A1, and the sections P1 to P4 are arranged as in the first embodiment. ing.

  More specifically, as shown in FIG. 6, the corner section A1 is composed of the (N + 1) -th winding electric wire n5 and the (N + 1) th winding in the section P1 in the straight section A2 disposed before the section A1 in the winding direction C. ) From the contact with the electric wire n4 of the winding, the electric wire n5 of the (N + 1) -th electric wire and the electric wire n6 of the (N + 2) -th electric winding in the section P2 disposed earlier in the winding direction C of this section A1. There is a section P4 that is a second separation section that switches to contact.

  In this corner section A1, the radius (R1) of the arc (curve) drawn by the outer-side electric wire 22b such as the N-th electric wire n4 and the (N + 2) -th electric wire n6 is, for example, 72.4 mm (hereinafter R72.4). ). On the other hand, the radius (R2) of the arc (curve) drawn by the (N + 1) -th winding wire n5 (the inner wire 22a) is, for example, 68.0 mm (R68.0), and the radii R1 and R2 are different from each other. .

  As described above, the outer wire 22b and the inner wire 22a of the pair of wires 22a and 22b have different radii, so that the distance of the straight section becomes longer and the number of abutting portions increases, thereby increasing the coil. Can be further improved. In addition, in terms of the relationship between the adjacent electric wires on the inner peripheral side and the outer peripheral side, the radius R1 of the electric wire 22b located on the outer peripheral side is larger than the radius R2 of the electric wire 22a located on the inner peripheral side. R2 (inner side) <R1 (outer side)

  The straight section A2 has a parallel section in which every other turn of the electric wire (for example, the electric wire n4 of the N-th turn and the electric wire n6 of the (N + 2) -th turn) are wired in parallel at a fixed interval. In this parallel section, three sections (sections P1, P2, P3) are provided, and are arranged in the winding direction C in the order of sections P2, P3, P1,.

  The section P3 is disposed at the center of the parallel section, and the (N + 1) -th wire n5 meanders obliquely within the above-mentioned interval and has another parallel wire (the wire n4 or the wire n6). ) Is a first separation section separated from the first section.

  Sections P1 and P2 are arranged on both sides of the section P3. These sections P1 and P2 are contact sections in which the (N + 1) th wire n5 is in contact with one of the adjacent parallel wires n4 and n6. The section P1 arranged on the left side of the section P3 is referred to as a first contact section. A section arranged on the right side of the section P3 is referred to as a second contact section P2.

  The section P1 is a section in which the Nth winding wire n4 and the (N + 1) th winding wire n5 are in contact with each other, and the (N + 1) th winding wire n5 is separated from the (N + 2) th winding wire n6. It is.

  The section P2 is a section in which the Nth electric wire n4 and the (N + 1) th electric wire n5 are separated from each other, and the (N + 1) th electric wire n5 and the (N + 2) th electric wire n6 are in contact with each other. is there.

  In the coil 20, the electric wire n5 is wired so as to cross obliquely between parallel electric wires (for example, between the electric wires n4 and n6) in a substantially central section P3 and a corner section A1 (section P4) of the straight section A2. .

Next, a method for manufacturing the coil 20 according to the second embodiment will be described.
In the second embodiment, the innermost circumference is the first winding, and the inner circumference side litz wire 22a is wound a plurality of times from the inner circumference side to the outer circumference side, and then along the inner circumference side litz wire 22a. The litz wire 22b on the outer peripheral side is wound a plurality of times from the inner peripheral side to the outer peripheral side to have a corner section A1 as shown in FIG. 5 and a straight section A2 on both sides of the winding direction C of the corner section A1. The coil 20 is formed. In this example, winding is started from the innermost side, but winding may be started from the outermost side.

  At this time, as shown in FIG. 6, in the corner section A1 (section P4), for example, the respective turns (the N-th, (N + 1) -th, and (N + 2) -th turns) of the electric wire n4, the electric wire n5, the electric wire n6, and the like. Are separated from each other and arranged in a curved shape.

  Subsequently, in the straight section A2, a parallel section in which every other turn of the electric wire (the electric wire n4 of the Nth turn and the electric wire n6 of the (N + 2) th turn) are arranged in parallel at a fixed interval is arranged.

  The section P3 in which the electric wire n5 of the (N + 1) th winding meanders within the interval between the electric wires n4 and n6 and is separated from the other parallel winding electric wires at the center in the parallel section is arranged in the straight section A2.

  In the straight section A2, on both sides of the section P3, sections P1 and P2 where the (N + 1) th wire n5 abuts on one of the parallel wires n4 and n6 are arranged.

  As described above, according to the second embodiment, in the central section P3 of the straight section A2 and the section P4 of the corner section A1, the inner litz wire 22a and the outer litz wire 22b that are adjacent to each other by winding are brought into contact with each other. By switching the parts, particularly, contact sections (sections P1 and P2) where different windings are in contact with each other on both sides of the corner A1 where the wires are separated from each other, and the windings of the coil 20 are bonded together. By arranging the portions (contact portions) to be radiated evenly in the radial direction from the center of the coil 20 and bonding the contact portions, the shape maintaining force of the coil having a gap can be increased.

  Here, referring to FIG. 7, a coil 20 of the second embodiment (the meandering coil of FIG. 5) and a comparative example (a coil in which a litz wire is spirally wound with a predetermined gap therebetween (hereinafter, referred to as a coil). The performance will be described in comparison with a “gap-wound coil”.

  The gap-wound coil is a coil in which a litz wire is spirally wound while providing a predetermined gap. The gap-wound coil is a standard coil as a sample in which a gap is provided at a predetermined interval for each turn of the litz wire, and it is desirable that the coil performance (characteristics) of the gap-wound coil be a specified value and be as close as possible to this.

  The test conditions were as follows. For each of the above two samples (gap wound coil and corner meandering coil), both ends of the coil were connected to an existing LCR meter, and the AC resistance was measured while changing the frequency from 0 to 200 kHz. It is. In FIG. 7, the value at the position where the frequency is 0 (about 14 mΩ) is a DC resistance.

  Referring to FIG. 7 of the measurement results, it can be seen that at any frequency, the corner meandering coil of the present invention has characteristics similar to those of the gap winding coil, and that the specified performance is obtained.

  The non-contact power supply device using the coil 20 (corner winding coil) shown in the first and second embodiments is disposed on a substrate 1 such as an aluminum plate and the upper surface of the substrate 1 as shown in FIG. And a coil 20 mounted (arranged) on the upper surface of the core core plate 2.

  Thereby, for example, a non-contact power transmission device on the primary side or a non-contact power reception device on the secondary side can be provided. Further, in order to fix the position of the coil 20 on the core core plate 2, the upper surface of the core core plate 2 may be coated with a mold resin or the like. Further, a groove for holding the shape of the coil 20 may be provided in the core core plate 2 itself. The substrate 1 may be an insulating plate material such as a resin plate in addition to a metal plate such as an aluminum plate.

  As described above, when the coil 20 is moved onto the magnetic core plate 2, the contact portions between the wires are bonded in advance, so that a support substrate (bobbin) having a groove, a spacer, and the like are required. The coil 20 can be handled in a state in which the shape is maintained without any change, the variation in inductance is small, and good handling properties (workability during coil manufacturing) can be obtained.

  Although the embodiment of the present invention has been described above, the above embodiment is presented as an example and is not intended to limit the scope of the invention. The new embodiment described above can be implemented in other various forms, and various omissions, replacements, and changes can be made without departing from the spirit of the invention. The above-described embodiment and its modified examples are included in the scope and gist of the invention, and are also included in the invention described in the claims and equivalents thereof.

  DESCRIPTION OF SYMBOLS 1 ... Aluminum plate (substrate), 2 ... Magnetic core board, 20 ... Coil, 21, 24 ... Crimp terminal, 22, 22a, 22b ... Litz wire.

Claims (7)

A coil formed by winding an electric wire a plurality of times,
From the beginning of winding, a corner section (where N is an integer of 1 or more) in which the Nth, (N + 1) th, and (N + 2) th wires are spaced apart and arranged in a curved shape;
On both sides in the winding direction of the corner section, a parallel section in which every other turn of the N-th wire and the (N + 2) -th wire are wired in parallel at a predetermined interval, and the (N + 1) ) A first separated section in which the winding electric wire meanders within the interval and separates from the other parallel winding electric wires in the parallel section, and is disposed on both sides of the first separated section; A coil having a straight section having first and second contact sections abutting on one of the parallel wound wires; The corner section is
From the contact of the (N + 1) th wire and the Nth wire in the straight section disposed in the winding direction, the straight section disposed in the winding direction at the end of the straight section. 2. The coil according to claim 1, further comprising a second separation section that is switched to contact between the (N + 1) -th wire and the (N + 2) -th wire. 3.   In the corner section, the radius of the arc (curve) drawn by the N-th wire and the (N + 2) -th wire or the center position of the radius and the arc (curve) drawn by the (N + 1) -th wire The coil according to claim 1, wherein the radius or the center position of the radius is different.   The coil according to claim 1, wherein a pair of wires including an inner wire and an outer wire are wound.   The coil according to any one of claims 1 to 4, wherein a portion where the electric wires come into contact with each other is adhered. A metal or resin substrate,
A magnetic core plate disposed on the substrate,
A non-contact power supply device comprising the coil according to any one of claims 1 to 5 disposed on the magnetic core plate. A method for manufacturing a coil in which a wire is wound a plurality of times to form a coil having a corner section and a straight section on both sides in a winding direction of the corner section,
In the corner section, from the beginning of winding, the N-th, (N + 1) -th and (N + 2) -th winding wires are separated from each other and arranged in a curved line;
Arranging, in the straight section, a parallel section in which every other turn of the N-th wire and the (N + 2) -th wire are wired in parallel at a fixed interval;
Arranging, in the straight section, a first separation section in which the (N + 1) th winding wire meanders within the interval and separates from the other parallel winding wires in the parallel section;
Arranging first and second contact sections in which the (N + 1) th wire is in contact with any of the parallel wires on both sides of the first separation section in the straight section. A method for manufacturing a coil, comprising:

Images