JP2020195224A - Power generation unit and manufacturing method thereof - Google Patents

Abstract

To provide a power generation unit and a manufacturing method thereof which can further improve the flatness of a coil substrate with respect to a cover member.SOLUTION: A power generation unit includes a cover member, an annular coil substrate bonded to the cover member via a first adhesive layer, and an annular magnetic track. The coil substrate includes a plurality of insulating substrates laminated in an axial direction of a rotating shaft, a plurality of flat coils arranged between the plurality of insulating substrates, and a second adhesive layer arranged between the insulating substrate and the flat coil to bond the insulating substrate and the flat coil. The first adhesive layer and the second adhesive layer are adhesive layers having the same material.SELECTED DRAWING: Figure 7

Description

The present disclosure relates to a power generation unit and a method for manufacturing the power generation unit.

A technique for adhering a plurality of members to each other via an adhesive member is known. Patent Document 1 discloses a structure in which a magnet and a case body are bonded to each other via an adhesive film in an electric motor.

Here, the power generation unit includes a coil substrate that is adhered to the cover member via an adhesive member, and a magnetic track that is arranged to face the coil substrate and is rotatable.

Japanese Unexamined Patent Publication No. 53-118713

In the power generation unit, the coil substrate and the magnetic track are arranged close to each other in order to improve the power generation efficiency. Therefore, it is desired to further improve the flatness of the coil substrate with respect to the cover member.

The present disclosure has been made in view of the above, and an object of the present invention is to provide a power generation unit and a method for manufacturing the power generation unit, which can further improve the flatness of the coil substrate with respect to the cover member.

The power generation unit according to one embodiment has a cover member which is a plate-shaped member, an annular coil substrate which is adhered to the cover member via a first adhesive layer, and a coil substrate which faces the opposite side of the cover member. A plurality of annular magnetic tracks arranged so as to rotate about a rotation axis, and generating electricity by the rotation of the magnetic track with respect to the coil substrate, the coil substrates are laminated in the axial direction of the rotation axis. A plurality of flat coils arranged between the insulating substrate and the plurality of insulating substrates, and the insulating substrate and the planar coil arranged between the insulating substrate and the planar coil are bonded to each other. A second adhesive layer is provided, and the first adhesive layer and the second adhesive layer are adhesive layers having the same material.

Since the first adhesive layer and the second adhesive layer are made of the same material, the shrinkage rate of the first adhesive layer and the second adhesive layer at the time of curing becomes uniform. Therefore, the flatness of the member located at the tip of the coil substrate in the stacking direction with respect to the cover member is improved as compared with the case where the cover member, the insulating substrate, and the flat coil are bonded by adhesive layers made of different materials. As a result, the coil substrate and the magnetic track can be arranged close to each other, and the power generation efficiency is improved.

As a preferred embodiment, the coil substrate has a protective film that is adhered to the insulating substrate located closest to the magnetic track side of the plurality of insulating substrates via a third adhesive layer, and the third is provided. The adhesive layer is an adhesive layer having the same material as the first adhesive layer and the second adhesive layer.

According to this, since the protective film is arranged on the most magnetic track side of the coil substrate, the protective film is scraped first even when the rotating magnetic track comes into contact with the coil substrate, so that the insulating substrate and the flat coil are separated. Less susceptible to damage. Further, the protective film is adhered to the insulating substrate via a third adhesive layer having the same material as the first adhesive layer and the second adhesive layer. Therefore, the flatness of the protective film with respect to the insulating substrate located closest to the magnetic track side is also improved, so that the flatness of the protective film with respect to the cover member is improved. Therefore, even when the protective film is provided, the coil substrate and the magnetic track can be arranged close to each other, and the power generation efficiency is improved.

As a preferred embodiment, the protective film is provided with a plurality of layers, and the plurality of protective films are adhered to each other via the third adhesive layer.

According to this, since the coil substrate is protected by a plurality of protective films, the insulating substrate and the flat coil are less likely to be damaged when the rotating magnetic track comes into contact with the coil substrate.

The method for manufacturing a power generation unit according to one aspect includes a first step of laminating a cover member which is a plate-shaped member, an adhesive film which is a first adhesive layer, and a coil substrate in this order to prepare a laminated body. The coil substrate in the first step includes a second step of vacuuming the laminate and a third step of heating the laminate while pressurizing the laminate in the lamination direction. A plurality of flat coils arranged between the sex substrate and each of the plurality of insulating substrates, and an adhesive film arranged between the insulating substrate and the planar coil and serving as a second adhesive layer. The first adhesive layer and the second adhesive layer have the same material.

The manufacturing method is a simple method because after laminating a plurality of members in order, the laminated body is evacuated, pressurized, and heated. In the power generation unit obtained by the above manufacturing method, since the first adhesive layer and the second adhesive layer are made of the same adhesive layer, the shrinkage rate of the first adhesive layer and the second adhesive layer when they are cured. Becomes uniform. Therefore, the flatness of the member located at the tip of the coil substrate in the stacking direction with respect to the cover member is improved as compared with the case where the cover member, the insulating substrate, and the flat coil are bonded by adhesive layers made of different materials. As a result, in the power generation unit, the coil substrate and the magnetic track can be arranged close to each other, and the power generation efficiency is improved.

As a desirable embodiment, in the coil substrate in the first step, a protective film is formed on the insulating substrate most separated from the cover member among the plurality of insulating substrates via an adhesive film serving as a third adhesive layer. Stacked.

In the power generation unit obtained by the manufacturing method, a protective film is provided on an insulating substrate farthest from the cover member. Therefore, when the rotating magnetic track is provided facing the protective film, the protective film is scraped first even when the magnetic track and the coil substrate come into contact with each other, so that the insulating substrate and the flat coil are not easily damaged. Further, the protective film is adhered to the insulating substrate via a third adhesive layer having the same material as the first adhesive layer and the second adhesive layer. Therefore, the flatness of the protective film on the insulating substrate farthest from the cover member is also improved, so that the flatness of the protective film on the cover member is improved. Therefore, when the rotating magnetic track is provided, the coil substrate and the magnetic track can be arranged close to each other even if the protective film is provided, and the power generation efficiency is improved.

According to the present disclosure, since the flatness of the coil substrate with respect to the cover member can be further improved, the power generation efficiency is improved by arranging the coil substrate and the magnetic track close to each other.

FIG. 1 is a perspective view of a bearing with a sensor including a power generation unit according to the present embodiment. FIG. 2 is an exploded perspective view of a bearing with a sensor including the power generation unit according to the present embodiment. FIG. 3 is an exploded perspective view of a bearing with a sensor including the power generation unit according to the present embodiment. FIG. 4 is a plan view showing a configuration example of the cover and the coil substrate of the present embodiment. FIG. 5 is a plan view showing a configuration example of the magnetic track of the present embodiment. FIG. 6 is a plan view showing a configuration example of the power generation unit of the present embodiment. FIG. 7 is a cross-sectional view of the plan view shown in FIG. 6 cut along the line VII-VII. FIG. 8 is a schematic view showing a cross section of the coil substrate and the cover of the modified example.

An embodiment (embodiment) for carrying out the invention will be described in detail with reference to the drawings. The present invention is not limited to the contents described in the following embodiments. In addition, the components described below include those that can be easily assumed by those skilled in the art and those that are substantially the same. Furthermore, the components described below can be combined as appropriate.

FIG. 1 is a perspective view of a bearing 1 with a sensor including the power generation unit 100 according to the present embodiment. 2 and 3 are exploded perspective views of the bearing 1 with a sensor including the power generation unit 100 according to the present embodiment. FIG. 2 is a view of the bearing 1 with a sensor viewed from the cover member 10 side, and FIG. 3 is a view of the bearing 1 with a sensor viewed from the bearing 120 side.

As shown in FIGS. 1 to 3, the bearing 1 with a sensor includes a power generation unit 100 and a bearing 120. The power generation unit 100 is attached to one side surface of the bearing 120. As shown in FIGS. 2 and 3, the power generation unit 100 includes a cover member 10, a coil substrate 20, a rotating portion 30, a circuit board 40, and a back cover 60. The bearing 120 has an outer ring 122 which is a fixed ring and an inner ring 121 which is a rotating ring. The back cover 60 is fixed to the outer ring 122, and the rotating portion 30 is fixed to the inner ring 121. The cover member 10 is fixed to the outer ring 122. Therefore, the rotating portion 30 rotates with respect to the cover member 10.

The cover member 10 has an annular (ring-shaped) top plate 12 having an opening H12 in the center, and a tubular side plate 11 connected to the periphery of the top plate 12. The cover member 10 is a plate-shaped member. The top plate 12 has a flat shape. The cover member 10 includes a magnetic material such as silicon steel plate, carbon steel (JIS standard SS400 or S45C), martensitic stainless steel (JIS standard SUS420) or ferritic stainless steel (JIS standard SUS430).

As shown in FIG. 3, the circuit board 40 is attached to one surface 12A of the front surface or the back surface of the top plate 12. One surface 12A is a surface on the bearing 120 side. The circuit board 40 has a power supply board 41 and a sensor board 42. For example, as shown in FIGS. 1 and 2, the power supply board 41 and the sensor board 42 are attached to the top plate 12 by fastening a bolt 19B made of a non-magnetic material such as brass to the female screw hole formed in the top plate 12. It is fixed. As shown in FIGS. 1 and 2, the bolt 19B has a length that does not protrude from the cover member 10 when attached to the cover member 10.

Further, the cover member 10 is provided with a through hole. As shown in FIGS. 1 and 2, the through hole is sealed with a non-magnetic lid 17 made of a non-magnetic material such as resin. An antenna 47 (see FIG. 4) is mounted on the sensor board 42. As shown in FIG. 1, the host device 150 includes a communication unit 151 and a computer 152. Since the cover member 10 has magnetism, it has a function of shielding electromagnetic waves from the antenna 47. However, the antenna 47 is arranged at a position facing the non-magnetic lid 17. Therefore, the electromagnetic wave WV of the antenna 47 can reach the communication unit 151 via the non-magnetic lid 17. The digital data received by the communication unit 151 is processed by the computer 152.

As shown in FIG. 4, the coil substrate 20 is attached to one surface 12A of the top plate 12. The coil substrate 20 is adhered (fixed) to one surface 12A of the top plate 12 via the first adhesive layer 201 (see FIG. 7).

As shown in FIGS. 2 and 3, the rotating portion 30 has a magnetic track 31, a ring-shaped base material 33, and a ring-shaped mounting jig 35. The base material 33 and the mounting jig 35 are made of metal. The magnetic track 31 is provided on one surface side of the base material 33. The mounting jig 35 is fixed to the other surface side of the base material 33. The mounting jig 35 projects from the other surface side of the base material 33 to one surface side of the base material 33 through the penetrating opening H33 located in the center of the base material 33. One surface side of the base material 33 is the surface side facing the cover member 10. The other surface side of the base material 33 is the surface side facing the back cover 60.

In the present embodiment, the magnetic track 31 and the base material 33 are collectively referred to as an encoder magnet. For example, an encoder magnet is formed by forming a plastic magnet on one surface of a metal base material and alternately magnetizing north and south poles on the surface of the formed plastic magnet. The mounting jig 35 is used to mount the encoder magnet on the shaft portion.

In the present embodiment, the power generation unit 100 can be made to correspond to various bearing sizes by changing the shape and the inner diameter dimension of the mounting jig 35. Further, the amount of power generated by the power generation unit 50 can be adjusted by changing the number of magnetic pole pairs 311 of the magnetic track 31 and the magnet material of the magnetic track 31. Further, in the present embodiment, in order to make the power generation unit 100 correspond to various bearing sizes, the rotating portion 30 is configured to be separable from the encoder magnet and the mounting jig 35. When the bearing size is limited to one type, the encoder magnet and the mounting jig 35 may be integrally molded. In this case, the productivity of the power generation unit 100 is improved.

FIG. 4 is a plan view showing a configuration example of the cover member 10 and the coil substrate 20 of the present embodiment. As shown in FIG. 4, a power supply board 41 and a sensor board 42 are attached to one surface 12A of the top plate 12. A power supply unit 43 is mounted on the power supply board 41. The power supply unit 43 converts the single-phase AC power supplied from the power generation unit into a DC voltage and supplies it to the sensor board 42. The power generation unit includes the coil substrate 20 and the magnetic track 31 (see FIG. 6).

As shown in FIG. 4, a sensor 44, a control unit 45 having a communication circuit, and an antenna 47 are mounted on the sensor board 42. The DC power from the power supply unit 43 is supplied to the sensor 44 and the control unit 45. The sensor 44, the control unit 45, and the antenna 47 may be composed of separate IC (Integrated Circuit) chips, or a part or all of them may be composed of one IC chip. Further, the sensor 44 includes, for example, an acceleration sensor 441, a temperature sensor 442, and an angle sensor 443.

As shown in FIG. 4, the coil substrate 20 includes a flexible substrate 21 (insulating substrate), a coil pattern 23 provided on the flexible substrate 21, and a plurality of yokes 25 provided on the flexible substrate 21. The shape of the flexible substrate 21 in a plan view is an annular shape (ring shape) of a perfect circle centered on the rotation axis Ax. The coil pattern 23 has a plurality of flat coils 23A to 23D (see FIG. 7) laminated in the thickness direction of the flexible substrate 21. The flat coil is a pattern of conductors patterned and provided on the surfaces of flexible substrates 21A to 21E (see FIG. 7), which are insulating substrates. In this embodiment, the conductor pattern is formed on a plurality of surfaces of the insulating substrate. The cross-sectional structure of the coil pattern 23 will be described later with reference to FIG. 7. The number of patterns of the coil pattern 23 is proportional to the number of laminated flat coils 23A to 23D. In the present embodiment, the number of stacked flat coils may be changed to adjust the amount of power generation depending on the application of the power generation unit 100.

As shown in FIG. 4, both ends of the coil pattern 23 are connected to the power supply board 41 via the lead wire 16. In this embodiment, the coil pattern 23 and the power supply board 41 may be connected to each other via an FPC (Flexible Printed Circuit) connector instead of the lead wire 16. Alternatively, the coil board 20 may be extended and directly connected to the power supply board 41. In the connection using the FPC connector, solder is not required, so that the productivity of the power generation unit 100 can be further increased.

As shown in FIG. 4, the coil pattern 23 has a plurality of first conductive portions 231 and a plurality of second conductive portions 232. The first conductive portion 231 extends in the circumferential direction of a circle centered on the rotation axis Ax in a plan view. The second conductive portion 232 extends in the radial direction of the circle centered on the rotation axis Ax.

The yoke 25 has a first yoke 25A located on one side of the first conductive portion 231 and a second yoke 25B located on the other side of the first conductive portion 231 in a plan view. For example, the first yoke 25A is located on the side farther from the rotation axis Ax than the first conductive portion 231. The second yoke 25B is located closer to the rotation axis Ax than the first conductive portion 231. However, the distance between the first yoke 25A and the rotating shaft Ax and the distance between the second yoke 25B and the rotating shaft Ax are the same length as each other.

For example, the coil pattern 23 is extended so that irregularities are alternately arranged along the circumferential direction of a circle centered on the rotation axis Ax in a plan view. One yoke 25 is arranged in each of the uneven recesses 233.

FIG. 5 is a plan view showing a configuration example of the magnetic track 31 of the present embodiment. As shown in FIG. 5, the shape of the magnetic track 31 in a plan view is an annular shape of a perfect circle centered on the rotation axis Ax. The magnetic track 31 has a plurality of magnetic pole pairs 311 including N pole 31N and S pole 31S. The plurality of magnetic pole pairs 311 are arranged in the circumferential direction of the circle centered on the rotation axis Ax. The north pole 31N and the south pole 31S are arranged alternately.

FIG. 6 is a plan view showing a configuration example of the power generation unit of the present embodiment. FIG. 6 shows a state in which the magnetic track 31 is superposed on the coil substrate 20. As shown in FIG. 6, one yoke 25 (for example, the first yoke 25A) and the other yoke 25 (for example, for example) are adjacent to each other in the circumferential direction of the circle centered on the rotation axis Ax (see FIGS. 4 and 5). , The second conductive portion 232 is located in the middle between the second yoke 25B). In the circumferential direction of the circle centered on the rotation axis Ax, the distance between the centers of the adjacent yokes 25 is 25p, and the distance between the centers of the adjacent second conductive portions 232 is 23p. For example, the distance 23p and the distance 25p are the same length as each other.

In the circumferential direction of the circle centered on the rotation axis Ax, the length 31L1 of the north pole 31N and the length 31L2 of the south pole 31S have the same length. Further, the length 31L1 of the north pole 31N and the length 31L2 of the south pole 31S are the same length as the distance 25p between the centers of the yoke 25.

As shown in FIG. 5, the distance between the centers of the adjacent N poles 31N and S poles 31S in the circumferential direction of the circle centered on the rotation axis Ax is 31p. The distance 31p between the centers of the north pole 31N and the south pole 31S is the same as the distance 25p between the centers of the yoke 25.

In the present embodiment, when the magnetic track 31 rotates relative to the coil substrate 20 about the rotation axis Ax, and the first yoke 25A faces the north pole, the second yoke 25B faces the south pole. To do. Further, when the first yoke 25A faces the S pole, the second yoke 25B faces the N pole. The first yoke 25A and the second yoke 25B do not face the same magnetic pole of the magnetic track 31. As a result, the phase of the change in the magnetic flux density passing through the first yoke 25A and the phase of the change in the magnetic flux density passing through the second yoke 25B are shifted by 180 °.

The first yoke 25A is located on the side farther from the rotation axis Ax than the first conductive portion 231. The second yoke 25B is located closer to the rotation axis Ax than the first conductive portion 231. Therefore, the induced current generated in the coil pattern 23 due to the change in the magnetic flux density passing through the first yoke 25A and the induced current generated in the coil pattern 23 due to the change in the magnetic flux density passing through the second yoke 25B flow in the same direction.

As described above, the power generation unit 100 includes a cover member 10, a coil substrate 20, and a magnetic track 31, and generates electricity by rotating the magnetic track 31 with respect to the coil substrate 20.

FIG. 7 is a cross-sectional view of the plan view shown in FIG. 6 cut along the line VII-VII. The stacking direction (thickness direction) of the flexible substrate and the flat coil is the same as the axial direction of the rotating shaft Ax. Of the stacking directions (thickness directions), the direction closer to the rotating portion 30 (the direction toward the upper side of the paper surface in FIG. 7) is set as the first direction D1, and the direction closer to the cover member 10 (toward the lower side of the paper surface in FIG. 7). Direction) is shown as the second direction D2. Further, the yoke 25 is not shown.

As shown in FIG. 7, for example, the coil substrate 20 includes a 5-layer flexible substrate 21A to 21E, a 4-layer flat coil 23A to 23D, a 1-layer insulating protective film 27, and an 8-layer second. It has an adhesive layer 202 to 209 and a third adhesive layer 210.

The flexible substrates 21A to 21E are insulating substrates. The flexible substrates are the first flexible substrate 21A, the second flexible substrate 21B, the third flexible substrate 21C, the fourth flexible substrate 21D, and the fifth flexible substrate in order along the first direction D1. 21E and are arranged. That is, in the present embodiment, five layers of flexible substrates 21A to 21E are arranged from the top plate 12 side toward the rotating portion 30 side. The thickness of the flexible substrates 21A to 21E is, for example, 25 μm.

In the plane coils 23A to 23D, the first plane coil 23A, the second plane coil 23B, the third plane coil 23C, and the fourth plane coil 23D are arranged in order along the first direction D1. Will be done. The planar coils are arranged between flexible substrates adjacent to each other in the stacking direction (thickness direction). The thickness of the flat coils 23A to 23D is, for example, 18 μm.

The second adhesive layers 202 to 209 are arranged between the respective flexible substrates 21A to 21E and the respective flat coils 23A to 23D, and adhere the insulating substrates and the flat coils adjacent to each other in the stacking direction. The details will be described below.

The first flexible substrate 21A and the first flat coil 23A are adhered to each other via the second adhesive layer 202. The first flat coil 23A and the second flexible substrate 21B are bonded to each other via the second adhesive layer 203. The second flexible substrate 21B and the second flat coil 23B are adhered to each other via the second adhesive layer 204. The second flat coil 23B and the third flexible substrate 21C are adhered to each other via the second adhesive layer 205. The third flexible substrate 21C and the third flat coil 23C are adhered to each other via the second adhesive layer 206. The third flat coil 23C and the fourth flexible substrate 21D are adhered to each other via the second adhesive layer 207. The fourth flexible substrate 21D and the fourth flat coil 23D are adhered to each other via the second adhesive layer 208. The fourth flat coil 23D and the fifth flexible substrate 21E are adhered to each other via the second adhesive layer 209. In this way, the second adhesive layers 202 to 209 are arranged between the flexible substrates 21A to 21E (insulating substrates) and the flat coils 23A to 23D, and the flexible substrates 21A to 21E and the flat coils 23A to 23D are adhered to each other. ..

Further, the protective film 27 is adhered to the fifth flexible substrate 21E via the third adhesive layer 210. The fifth flexible substrate 21E is a flexible substrate located closest to the magnetic track 31 side among the plurality of flexible substrates (flexible substrates 21A to 21E).

The coil substrate 20 is adhered to one surface 12A of the top plate 12 via the first adhesive layer 201. In other words, the first flexible substrate 21A and one surface 12A of the top plate 12 are adhered to each other via the first adhesive layer 201.

Here, the first adhesive layer 201, the second adhesive layer 202, and the third adhesive layer 210 have the same material. For example, an adhesive of a thermosetting resin such as a polyimide resin or an epoxy resin can be applied.

The first adhesive layer 201, the second adhesive layers 202 to 209, and the third adhesive layer 210 all have the same material. For example, the first adhesive layer 201, the second adhesive layers 202 to 209, and the third adhesive layer 210 may all contain a thermosetting resin such as a polyimide resin or an Eposiki resin. The thickness of the first adhesive layer 201, the second adhesive layers 202 to 209, and the third adhesive layer 210 is, for example, 35 μm.

Further, the five-layer flexible substrates 21A to 21E, the protective film 27, the first adhesive layer 201, the second adhesive layers 202 to 209, and the third adhesive layer 210 may all be resins having the same material. For example, all of them may contain a thermosetting resin such as a polyimide resin or an epoxy resin.

The manufacturing method of the power generation unit 100 will be briefly described below.

First, in the first step, the cover member 10, the flexible substrates 21A to 21E, the flat coils 23A to 23D, the adhesive film to be the first adhesive layer 201, the adhesive film to be the second adhesive layer 202 to 209, and the third adhesive layer 210. The adhesive film and the protective film 27 are laminated. In other words, in the first step, the cover member 10 which is a plate-shaped member, the adhesive film which becomes the first adhesive layer 201, the coil substrate 20, the adhesive film which becomes the third adhesive layer 210, and the protective film 27. Are laminated in this order to prepare a laminated body. The coil substrate 20 in the first step is arranged between the first flexible substrate 21A to the fifth flexible substrate 21E (a plurality of insulating substrates) and the first flexible substrate 21A to the fifth flexible substrate 21E, respectively. A first flat coil 23A to a fourth flat coil 23D (a plurality of flat coils), and an adhesive film arranged between the insulating substrate and the flat coil to form a second adhesive layer 202 to 209. , Have.

Next, in the second step, the laminated body is housed inside the vacuum container and evacuated. Then, in the third step, the laminated body is heated while pressurizing the laminated body from above and below in the stacking direction.

As a result, the coil substrate 20 and the cover member 10 adhered to the coil substrate 20 are manufactured.

As described above, the power generation unit 100 according to the present embodiment is an annular coil substrate 20 that is bonded to the cover member 10 and one surface 12A of the top plate 12 of the cover member 10 via the first adhesive layer 201. And an annular magnetic track 31 which is arranged so as to face the cover member 10 of the coil substrate 20 and rotates about the rotation axis Ax. The coil substrate 20 includes a first flexible substrate 21A to a fifth flexible substrate 21E (a plurality of insulating substrates) laminated in the axial direction of the rotation axis Ax, and a first flexible substrate 21A to a fifth flexible substrate 21E. The first flat coil 23A to the fourth flat coil 23D (a plurality of flat coils) arranged between the two, and the second adhesive layers 202 to 209 for adhering the insulating substrate and the flat coil. Has. The first adhesive layer 201 and the second adhesive layers 202 to 209 are adhesive layers having the same material.

The first adhesive layer 201 and the second adhesive layers 202 to 209 are adhesive layers having the same material. That is, the cover member 10, the flexible substrates 21A to 21E, and the flat coils 23A to 23D are adhered to each other by using an adhesive layer made of the same material. Therefore, with respect to the first adhesive layer 201 and the second adhesive layers 202 to 209, the shrinkage rate at the time of curing becomes uniform. That is, since the shrinkage ratio of each of the plurality of adhesive layers arranged between the adjacent members in the stacking direction becomes uniform, the cover member 10, the flexible substrates 21A to 21E, and the flat coils 23A to 23D are separate from each other. The flatness of the member located at the tip of the coil substrate 20 in the stacking direction is improved with respect to the cover member 10 as compared with the case where the adhesive layer of the material is used for bonding. As a result, the coil substrate 20 and the magnetic track 31 can be arranged close to each other, and the power generation efficiency is improved.

The coil substrate 20 is a third on a fifth flexible substrate 21E, which is an insulating substrate located closest to the magnetic track 31 among the first flexible substrate 21A to the fifth flexible substrate 21E (plurality of insulating substrates). The third adhesive layer 210 has a protective film 27 bonded via the adhesive layer 210, and the third adhesive layer 210 is an adhesive layer having the same material as the first adhesive layer 201 and the second adhesive layers 202 to 209.

The protective film 27 is arranged on the most magnetic track 31 side of the coil substrate 20. Therefore, when the rotating magnetic track 31 comes into contact with the coil substrate 20, the protective film 27 is scraped off, so that the insulating substrate (first flexible substrate 21A to fifth flexible substrate 21E) and the flat coil (first flexible substrate 21E) are scraped. The flat coil 23A to the fourth flat coil 23D) are not easily damaged. Further, the protective film 27 is adhered to the insulating substrate via the third adhesive layer 210. The third adhesive layer 210 has the same material as the first adhesive layer 201 and the second adhesive layers 202 to 209. Therefore, the flatness of the protective film 27 located closest to the magnetic track 31 is also improved.

The first method of manufacturing the power generation unit 100 is to create a laminated body by laminating a cover member 10 which is a plate-shaped member, an adhesive film which becomes a first adhesive layer 201, and a coil substrate 20 in this order. The coil substrate 20 in the first step includes a step, a second step of vacuuming the laminate, and a third step of heating the laminate while pressurizing the laminate in the lamination direction. 1st flexible substrate 21A to 5th flexible substrate 21E (plurality of insulating substrates) and 1st flat coil 23A to 5th arranged between each of the 1st flexible substrate 21A to the 5th flexible substrate 21E. It has the flat coil 23D (plurality of flat coils) of No. 4 and an adhesive film arranged between the insulating substrate and the flat coil and serving as a second adhesive layer 202 to 209, and has a first adhesive layer 201. And the second adhesive layers 202 to 209 have the same material.

The manufacturing method is a simple method because after laminating a plurality of members in order, the laminated body is evacuated, pressurized, and heated. In the power generation unit 100 obtained by the above manufacturing method, since the first adhesive layer 201 and the second adhesive layer are made of the same adhesive layer, when the first adhesive layer 201 and the second adhesive layer are cured. Shrinkage rate becomes uniform. Therefore, the flatness of the member located at the tip of the coil substrate 20 in the stacking direction is improved as compared with the case where the cover member 10, the insulating substrate, and the flat coil are bonded by adhesive layers made of different materials. As a result, in the power generation unit, the coil substrate 20 and the magnetic track 31 can be arranged close to each other, and the power generation efficiency is improved.

Further, the protective film 27 is laminated on the fifth flexible substrate 21E via an adhesive film serving as a third adhesive layer 210.

Since the rotating magnetic track 31 is provided facing the protective film 27, the protective film 27 is scraped first even when the magnetic track and the coil substrate 20 come into contact with each other, and the insulating substrate and the flat coil are not easily damaged. Further, the protective film 27 is adhered to the insulating substrate via the third adhesive layer 210. Therefore, the flatness of the protective film 27 with respect to the fifth flexible substrate 21E is also improved, so that the flatness of the protective film 27 with respect to the cover member 10 is improved. Therefore, even if the protective film 27 is provided, the coil substrate 20 and the magnetic track 31 can be arranged close to each other, and the power generation efficiency is improved.

Next, a modified example will be described with reference to FIG. However, the same reference numerals are given to the parts having the same structure as that of the above-described embodiment, and the description thereof will be omitted. The yoke 25 is not shown.

As shown in FIG. 8, the coil substrate 20A according to the modified example is provided with two protective films. That is, the protective film 27A according to the modified example has a first protective film 271 and a second protective film 272. The first protective film 271 is adhered to the first direction D1 side (magnetic track 31 side) of the fifth flexible substrate 21E via the third adhesive layer 210. The second protective film 272 is adhered to the first direction D1 side (magnetic track 31 side) of the first protective film 271 via the third adhesive layer 211.

As described above, in the coil substrate 20A according to the modified example, the protective film 27A is provided with a plurality of layers (first protective film 271 and second protective film 272). The first protective film 271 and the second protective film 272 are adhered to the fifth flexible substrate 21E via the third adhesive layers 210 and 211. Therefore, when the rotating magnetic track 31 comes into contact with the coil substrate 20A, the insulating substrate and the flat coil are less likely to be damaged.

10 Cover member 20, 20A Coil substrate 21A First flexible substrate (insulating substrate)
21B Second flexible substrate (insulating substrate)
21C Third flexible substrate (insulating substrate)
21D 4th flexible substrate (insulating substrate)
21E Fifth flexible substrate (insulating substrate)
23A 1st flat coil (flat coil)
23B Second flat coil (flat coil)
23C Third flat coil (flat coil)
23D 4th flat coil (flat coil)
27, 27A Protective film 31 Magnetic track 100 Power generation unit 201 First adhesive layer 202 to 209 Second adhesive layer 210, 211 Third adhesive layer

Claims (5)

A cover member that is a plate-shaped member and
An annular coil substrate that is bonded to the cover member via the first adhesive layer,
An annular magnetic track, which is arranged to face the cover member of the coil substrate and rotates about a rotation axis, is provided.
Power is generated by the rotation of the magnetic track with respect to the coil substrate.
The coil substrate includes a plurality of insulating substrates laminated in the axial direction of the rotating shaft, a plurality of planar coils arranged between the plurality of insulating substrates, and the insulating substrate and the planar coil. It has a second adhesive layer which is arranged between the two and adheres the insulating substrate and the flat coil.
The first adhesive layer and the second adhesive layer are power generation units which are adhesive layers having the same material. The coil substrate has a protective film that is adhered to the insulating substrate located closest to the magnetic track side of the plurality of insulating substrates via a third adhesive layer.
The power generation unit according to claim 1, wherein the third adhesive layer is an adhesive layer having the same material as the first adhesive layer and the second adhesive layer. The power generation unit according to claim 2, wherein a plurality of layers of the protective film are provided, and the plurality of protective films are bonded to each other via the third adhesive layer. The first step of creating a laminated body by laminating a cover member which is a plate-shaped member, an adhesive film which is a first adhesive layer, and a coil substrate in this order.
The second step of evacuating the laminate and
Including a third step of heating the laminate while pressurizing the laminate in the lamination direction.
The coil substrate in the first step is arranged between a plurality of insulating substrates, a plurality of flat coils arranged between the plurality of insulating substrates, and the insulating substrate and the planar coils. And has an adhesive film that serves as a second adhesive layer.
The first adhesive layer and the second adhesive layer have the same material.
Manufacturing method of power generation unit. In the coil substrate in the first step, a protective film is laminated on the insulating substrate most separated from the cover member among the plurality of insulating substrates via an adhesive film serving as a third adhesive layer.
The method for manufacturing a power generation unit according to claim 4.

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