JP2023124710A - Coil component, coil, power transmission device, power reception device, and electric power transmission system - Google Patents

Abstract

To provide a coil component which can secure good strength and good coil characteristics.SOLUTION: A coil component 10A according to one embodiment includes: a coil 11 including a spiral shaped conductor 11E including multiple turn parts 12n arranged at the radial outer side from a center axis C of the spiral shape; a case 20 serving as a storage member for storing the coil 11; and one or multiple pillars 30 which extend in an axial direction of the coil 11 and pass through the coil 11. At least one of both ends of the pillar 30 is connected to an inner surface of the case 20.SELECTED DRAWING: Figure 3

Description

The present disclosure relates to coil components, coils, power transmitting devices, power receiving devices, and power transmission systems.

A wireless power transmission system that transmits power in a non-contact manner is becoming popular.

When transmitting a large amount of electric power without contact, a large high-frequency current is passed through a resonance circuit including a coil. At this time, the amount of heat generated by the coil increases. The amount of heat generated by the coil increases due to, for example, the skin effect.

When a litz wire is used as the coil, the skin effect is suppressed. Therefore, heat generation of the coil can be suppressed. However, since the litz wire is formed by twisting a large number of enameled wires, the production cost is high and the production is troublesome. Higher power systems can have larger coils, which can increase manufacturing costs and complexity.

On the other hand, there is also known a technique of adopting a planar coil having a spiral shape, a plate shape, and a conductor wire having a rectangular cross section (see Patent Document 1). With such a planar coil, the manufacturing efficiency can be improved regardless of the size of the coil. Such planar coils are therefore suitable for high power systems where the coil size can be large.

In a wireless power transmission system for electric vehicles, a power transmission device is installed on a road surface such as a parking lot, and a power reception device is installed in the electric vehicle. For example, when the planar coil is used for an electric vehicle, the height dimension can be particularly suppressed in both the power transmitting device and the power receiving device. Therefore, the planar coil described above functions beneficially, for example, in the field of vehicles, where space constraints are severely imposed.

Japanese Patent Application Laid-Open No. 2021-27112

For example, in a power transmission device installed on a road surface, a coil is normally housed in a case. The case usually has a bottom wall, side walls rising from the bottom wall and surrounding the outer periphery of the coil, and a top wall closing the side walls.

When the planar coil disclosed in Patent Document 1 is housed in the case of the power transmission device, the planar coil may be held in a state separated from each of the top wall and the bottom wall. However, in this configuration, for example, when the load from the vehicle is transmitted from the top wall of the case to the side wall, only the side wall bears the load. Also, a situation can occur in which the top wall bends and touches the planar coil, causing the planar coil to bend or the spacer to break. Therefore, there is a possibility that the strength of the power transmission device may not be sufficient.

Although it is conceivable to make the case heavy in order to improve the strength of the case, in this case, there is a possibility that desired coil characteristics cannot be obtained due to restrictions on the coil size.

The present disclosure has been made in consideration of the above circumstances, and an object thereof is to provide a coil component, a coil, a power transmission device, a power reception device, and a power transmission system that can ensure good strength and good coil characteristics. be.

A coil component according to one embodiment includes a coil having a spiral-shaped conductor, the conductor including a plurality of turn portions arranged radially outward from a central axis of the spiral, and the coil and one or more struts extending in the axial direction of the coil and passing through the coil, wherein at least one of both ends of the strut is connected to the inner surface of the storage member a coil component that is in contact with the inner surface of the housing member or faces the inner surface away from the inner surface of the housing member.

The one or more struts may include a first strut located radially inward of the innermost turn portion.

The one or more struts may include second struts passing between the radially adjacent turn portions.

The second strut may be positioned between the second radially inner turn portion of the coil and the second radially outer turn portion of the coil. .

The gap between the radially adjacent turn portions through which the second support passes is greater than the width of the first region through which the second support passes in the radial direction. and a second region having a narrow width at .

An inner turn portion positioned radially inward and an outer turn portion positioned radially outward of the radially adjacent turn portions forming a gap through which the second strut passes. may have a first straight portion and a second straight portion extending along a straight line, and a corner portion connecting the first straight portion and the second straight portion. The corner portion has an arc shape, a straight line shape, or a polygonal line shape along the arc, the first straight portion extends straight from one end of the corner portion, and the second straight portion extends from the corner portion. may extend linearly from the other end of the In the inner turn portion and the outer turn portion, the first straight portions are adjacent to each other in the radial direction, the second straight portions are adjacent to each other in the radial direction, and the outer turn portions are adjacent to each other in the radial direction. The distance between both ends of the corner portion is smaller than the distance between both ends of the corner portion of the inner turn portion, and the first region is formed between the corner portion of the inner turn portion and the outer turn portion. It may be a region between the corner portions.

The corner portion of the inner turn portion and the corner portion of the outer turn portion are arc-shaped, and the curvature of the corner portion of the inner turn portion is greater than the curvature of the corner portion of the outer turn portion. may be smaller.

When viewed in the axial direction of the coil, the storage member has a rectangular shape, and when viewed in the axial direction of the coil, the second strut is positioned on a diagonal line of the storage member, or It may be located within a range sandwiched between line segments extending at positions obtained by rotating the diagonal line of the member by ±10 degrees around the center of the storage member.

An inner turn portion positioned radially inward and an outer turn portion positioned radially outward of the radially adjacent turn portions forming a gap through which the second strut passes. may have a straight portion extending along a straight line. The second strut may pass between the linear portion of the inner turn portion and the linear portion of the outer turn portion that are adjacent to each other.

Further, the coil component according to one embodiment further includes an insulating member that is in contact with the coil in the axial direction of the coil, and the insulating member includes the turn portions adjacent to each other in the radial direction through which the second struts pass. A through-hole may be formed to overlap the gap between and, and the second support may pass through the through-hole and the gap.

An inner turn portion positioned radially inward and an outer turn portion positioned radially outward of the radially adjacent turn portions forming a gap through which the second strut passes. has a straight portion extending along a straight line, and the through hole is formed in the gap between the straight portion of the inner turn portion and the straight portion of the outer turn portion adjacent to each other. May overlap.

The coil may be spaced from an inner surface of the housing member to which the strut is connected or abuts or faces.

The housing member may have a side wall portion surrounding the outer periphery of the coil and an end wall portion closing the side wall portion, and the post may be integrally connected to the end wall portion.

The post may be a separate member from the storage member, and may be sandwiched between opposing portions on the inner surface of the storage member, or may be sandwiched between the inner surface of the storage member and another member.

The posts may be non-magnetic and insulating.

A coil according to one embodiment includes a spiral-shaped conductor, the conductor includes a plurality of turn portions arranged radially outward from a center axis of the spiral shape, and the plurality of turn portions each of the radially inwardly positioned inner turn portion and the radially outwardly positioned outer turn portion in at least one pair of the radially adjacent turn portion pairs in has a first straight portion and a second straight portion extending along a straight line, and a corner portion connecting the first straight portion and the second straight portion, wherein the corner portion has an arc shape or a straight shape or a polygonal line along an arc, the first linear portion linearly extending from one end of the corner portion, the second linear portion linearly extending from the other end of the corner portion, In the turn portion and the outer turn portion, the first straight portions are adjacent to each other in the radial direction, and the second straight portions are adjacent to each other in the radial direction. The distance between the inner turn portion and the outer turn portion is smaller than the distance between both ends of the corner portion of the inner turn portion, and the gap between the inner turn portion and the outer turn portion is the corner portion of the inner turn portion and the outer turn portion. The coil includes a first region between the corner portions of the side turn portion and a second region having a width in the radial direction narrower than that of the first region in the radial direction.

Further, a power transmission device according to one embodiment includes the coil component described above.
Further, a power receiving device according to one embodiment includes the coil component described above.
Further, a power transmission system according to one embodiment includes a power transmission device and a power reception device, and at least one of the power transmission device and the power reception device includes the coil component.

According to the present disclosure, good strength and good coil characteristics can be ensured in the coil component.

1 is a diagram schematically showing a wireless power transmission system to which a coil component according to an embodiment can be applied; FIG. 1 is a perspective view of a coil component according to a first embodiment; FIG. FIG. 3 is a cross-sectional view of the coil component taken along line III-III in FIG. 2; 1 is a perspective view of a coil and an insulating member that constitute a coil component according to a first embodiment; FIG. 3 is a plan view of a coil and an insulating member that constitute the coil component according to the first embodiment; FIG. FIG. 10 is a perspective view of a coil component according to a second embodiment; FIG. 8 is a perspective view of a coil and an insulating member that constitute a coil component according to a second embodiment; It is a figure explaining the manufacturing method of the coil component which concerns on 2nd Embodiment. It is a figure explaining the manufacturing method of the coil component which concerns on 2nd Embodiment. It is a figure explaining the manufacturing method of the coil component which concerns on 2nd Embodiment. FIG. 11 is a perspective view of a coil component according to a third embodiment; FIG. 11 is a perspective view of a coil and an insulating member that constitute a coil component according to a third embodiment; FIG. 11 is a perspective view of a coil component according to a fourth embodiment; FIG. 11 is a perspective view of a coil and an insulating member that constitute a coil component according to a fourth embodiment; FIG. 11 is a cross-sectional view of a coil component according to a fifth embodiment; FIG. 11 is a cross-sectional view of a coil component according to a sixth embodiment;

Each embodiment will be described below with reference to the drawings.

In this specification, terms such as "sheet", "film" and "plate" are not to be distinguished from each other based only on the difference of names. Therefore, for example, the term "sheet" is a concept that includes members that can also be called films or plates.

In addition, in this specification, the term "sheet surface (plate surface, film surface)" refers to the plane direction (surface direction).

<Wireless power transmission system>
FIG. 1 schematically shows a wireless power transmission system S to which coil components according to embodiments described later can be applied. First, a wireless power transmission system S (hereinafter abbreviated as power transmission system S) will be described with reference to FIG.

A power transmission system S includes a power transmission device 1 and a power reception device 2 . The power transmission device 1 includes a coil component 10 and a high frequency current supply section 1A. The coil component 10 in the power transmission device 1 functions as a power transmission coil. The high-frequency current supply unit 1A supplies high-frequency current to the coil component 10 as a power transmission coil.

Power receiving device 2 includes a coil component 10 and a conversion unit 2A. The coil component 10 in the power receiving device 2 functions as a power receiving coil. Conversion unit 2A shapes the high-frequency current generated in coil component 10 . The conversion unit 2A has a rectifying circuit and the like that converts a high frequency current into a direct current.

When power is transmitted wirelessly (non-contact) from the power transmission device 1 to the power reception device 2, the power transmission device 1 supplies a high-frequency current of a predetermined frequency from the high-frequency current supply unit 1A to the coil component 10 as a power transmission coil. . At this time, a magnetic field is generated in the coil component 10 by electromagnetic induction. Under the influence of this magnetic field, a high-frequency current is generated in the coil component 10 as the power receiving coil in the power receiving device 2 . The converter 2A converts this high-frequency current into a direct current, and supplies the converted direct current to, for example, a battery (not shown).

The power transmission system S shown in FIG. 1 employs a magnetic resonance method as a power transmission method. However, the power transmission system S may be configured as an electromagnetic induction type power transmission system. Also, the power transmission system S is configured as a system for wirelessly transmitting power to an electric vehicle. In this case, the power transmission device 1 is installed on a road, a parking lot, or the like. The power receiving device 2 is installed in an electric vehicle.

However, the application of the power transmission system S is not limited to power transmission to electric vehicles. For example, the power transmission system S may be used for power transmission to flying objects such as drones and robots. Also, the power transmission system S may be used for power transmission to submersibles and exploration robots in the sea. In addition, the application of the coil component according to the embodiment is not limited to the wireless power transmission system. For example, coil components according to embodiments may be used in transformers, DC-DC converters, antennas, and the like.

Each of the power transmission systems S includes, as the coil component 10, one of the coil components according to each embodiment described later. Note that the coil component of the same embodiment may be used in each of the power transmission device 1 and the power reception device 2 . Further, coil components of different embodiments may be used in each of the power transmission device 1 and the power reception device 2 . Alternatively, one of the power transmitting device 1 and the power receiving device 2 may use the coil component of the embodiment, and the other may use another type of coil component. A coil component according to each embodiment will be described below.

<First embodiment>
FIG. 2 is a perspective view of the coil component 10A according to the first embodiment. FIG. 3 is a cross-sectional view of the coil component 10A along line III-III in FIG.

As shown in FIGS. 2 and 3, the coil component 10A includes a coil 11, a case 20, a post 30, a spacer member 40, a magnetic shield member 44, an insulating member 46, a first connection terminal 51, a second 2 connection terminals 52 are provided.

The case 20 has a bottom wall portion 22 , a side wall portion 23 rising from the bottom wall portion 22 , and a top wall portion 24 provided at the tip of the side wall portion 23 . In FIG. 2, the top wall portion 24 is shown separated for convenience of explanation. Also, the first connection terminal 51 and the second connection terminal 52 are simply indicated by a chain double-dashed line.

Case 20 accommodates coil 11 , spacer member 40 , magnetic shield member 44 , and insulating member 46 . The struts 30 are connected to the top wall portion 24 as will be described later, and are positioned within the space surrounded by the bottom wall portion 22 , the side wall portions 23 and the top wall portion 24 . The spacer member 40, the magnetic shield member 44, and the insulating member 46 are arranged on the bottom wall portion 22 in this order. The spacer member 40, the magnetic shield member 44, and the insulating member 46 are sheet-like and overlap each other. The spacer member 40 is interposed between the bottom wall portion 22 and the magnetic shield member 44 and the insulating member 46 to support the magnetic shield member 44 and the insulating member 46 . The coil 11 is a planar coil, as will be described later, and is integrated with a sheet-like insulating member 46 . Thereby, the coil 11 is held in a state separated from the bottom wall portion 22 .

The spacer member 40, the magnetic shield member 44, the insulating member 46, and the coil 11 are surrounded by the side wall portion 23 and covered with the top wall portion 24 from above in FIG.

The column 30 is provided between the bottom wall portion 22 and the top wall portion 24 , and the bottom wall portion 22 and the top wall portion 24 are positioned so as to sandwich the column 30 . In this embodiment, one end of the support 30 is connected to the top wall portion 24 and the other end of the support 30 is in contact with the bottom wall portion 22 . As a result, the load received by the top wall portion 24 is transmitted to the side wall portion 23 and the support column 30 , and the load received by the top wall portion 24 is supported by the side wall portion 23 and the support column 30 . In addition, in FIG. 2, for convenience of explanation, the top wall portion 24 and the strut 30 are shown in a separated state. Each part constituting the coil component 10A will be described in detail below.

(coil)
4 is a perspective view of the coil 11 and the insulating member 46. FIG. FIG. 5 is a plan view of the coil 11 and the insulating member 46. FIG. The coil 11 has a spiral shape and is formed from an electrically conductive material. Although the coil 11 is made of copper in the present embodiment, the coil 11 may be made of any conductive material, such as aluminum. In FIG. 5, the range of the coil 11 is dotted for convenience of explanation.

The coil 11 is plate-shaped. That is, the coil 11 is a planar coil. Specifically, the coil 11 is a planar coil of non-litz wire. As shown in FIG. 3, the cross-sectional shape of the conductor in the direction orthogonal to the winding direction of the coil 11 is rectangular.

Reference character C shown in FIGS. 2 to 5 indicates the central axis of the coil 11 passing through the center of the spiral shape of the coil 11 . Hereinafter, when referring to the axial direction of the coil 11, the direction means the direction extending on the central axis C or the direction parallel to the central axis C. As shown in FIG. A direction orthogonal to the central axis C is called a radial direction.

Coil 11 includes a conductor 11E having a spiral shape. The conductor 11E includes a plurality of turn portions 12n. The plurality of turn portions 12n are arranged radially outward from the central axis C of the spiral shape. The plurality of turn portions 12n are connected so as to gradually move away from the center axis C toward the radially outward direction from the center axis C, thereby forming a spiral shape.

The turn portion 12n has a shape in which a linear conductor portion circles around the central axis C by 360 degrees without forming a ring. In the case of a so-called planar coil, both ends of the turn portion 12n are shifted in the radial direction. In the plurality of turn portions 12n, the radially outer end of one turn portion 12n is connected to the radially inner end of another turn portion 12n, and the other turn portion 12n is connected to the center axis line. Extends away from C.

“n” in turn portion 12 n means a variable that takes a number from 1 corresponding to the number of turns of coil 11 . Below, the turn portion 121 may be referred to as the turn portion 121 that is closest to the central axis C among the plurality of turn portions 12n. Also, the turn portion connected to the radially outer end of the turn portion 121 may be referred to as a turn portion 122 , and the turn portion connected to the radially outer end of the turn portion 122 may be referred to as a turn portion 122 . , may be referred to as a turn portion 123 . In the example of FIGS. 4 and 5, the number of turns is 9, and the plurality of turn portions 12n are composed of 9 turn portions 121-129. The turn portion 129 corresponds to the outermost turn portion.

It should be noted that the radially inner side of a certain member means a position closer to the central axis C than the member concerned. Further, the radially outward direction of a certain member means a position away from the member in the radially outward direction. For example, the term “inside the coil 11 in the radial direction” means a position closer to the center axis C than the innermost turn portion 121 . When it is said to be “outward in the radial direction of the coil 11 ”, it means a position away from the outermost turn portion 129 in the radial direction.

In the illustrated example, the first turn portion 12n from the radially inner side of the coil 11 is the turn portion 121, and the second radially inner turn portion 12n of the coil 11 is the 122. . The first turn portion 12 n from the radially outer side of the coil 11 is the turn portion 129 , and the second radially outer turn portion 12 n of the coil 11 is 128 . Further, when describing the positional relationship between the two members, the member may be referred to as a radially inner member and may be referred to as a radially outer member. In this case, the member closer to the central axis C of the two members corresponds to the radially inner member. Also, of the two members, the member located radially farther from the radially inner member corresponds to the radially outer member.

When describing items common to each of the plurality of turn portions 12n below, they are basically referred to as the turn portions 12n.

In this embodiment, the turn portion 12n is wound in a rectangular shape. As a result, the shape of the coil 11 in plan view also becomes rectangular. The turn portion 12n shown in FIG. 5 includes a first straight portion 131n, a first corner portion 132n, a second straight portion 133n, a second corner portion 134n, a third straight portion 135n, a third corner portion 136n, and a fourth straight portion 137n. , the fourth corner portion 138n and the fifth straight portion 139n are connected in this order to form a rectangular shape. The starting end of the first linear portion 131n and the terminal end of the fifth linear portion 139n are positioned on the reference line St radially extending from the center axis C. As shown in FIG. The starting end of the first straight portion 131n of the next turn portion 12n is connected to the end of the fifth straight portion 139n.

"n" in the above symbols 131n to 139n also means a variable that takes a number from 1 corresponding to the number of turns of the coil 11. As shown in FIG. Hereinafter, for example, the above-described portions of the turn portion 121 are referred to as a first straight portion 1311, a first corner portion 1321, a second straight portion 1331, a second corner portion 1341, a third straight portion 1351, a third corner portion 1361, A fourth straight portion 1371 , a fourth corner portion 1381 and a fifth straight portion 1391 may be called.

More specifically, the shape of the turn portion 12n is that the first corner portion 132n connects the first straight portion 131n and the second straight portion 133n that are separated from each other. The first straight portion 131n, the first corner portion 132n, and the second straight portion 133n are connected so as to bend like a bow. In this example, the first corner portion 132n is arc-shaped, and the first straight portion 131n extends along a straight line from one end of the first corner portion 132n. The second straight portion 133n extends along a straight line from the other end of the first corner portion 132n.

Then, the second straight portion 133n, the second corner portion 134n and the third straight portion 135n are connected in the same manner as the first straight portion 131n, the first corner portion 132n and the second straight portion 133n, and the third straight portion 135n, the third corner portion 136n and the fourth straight portion 137n are connected, and the fourth straight portion 137n, the fourth corner portion 138n and the fifth straight portion 139n are connected.

Although the turn portion 12n shown in FIG. 5 is wound in a rectangular shape, the shape of the turn portion 12n is not particularly limited. For example, part or all of the turn portion 12n may have a circular shape. Also, the corner portions 132n, 134n, 136n, and 138n described above may be linear or polygonal along an arc. In addition, the spiral shape referred to in this specification and the present disclosure means the shape of a spirally wound plane curve. The planar curve referred to here also includes a planar pattern that bends and continues like a polygonal line as shown in the drawing. Also, in other words, the spiral shape is a shape that circles around the central axis C of the coil 11 so as to gradually move outward.

Also, the number of pairs of the plurality of radially adjacent turn portions 12n in the conductor 11E is eight because the number of turns is nine. In the present embodiment, the pairs of radially adjacent turn portions 12n include those in which the width of the gap between the radially adjacent turn portions 12n is constant and in which the gap width is not constant.

Specifically, the width of the gap between the fourth turn portion 124 and the fifth turn portion 125 from the radially inner side of the coil 11 is not constant, and the gap is a radially wide first region. B1 and a second region B2 having a radial width narrower than the radial width of the first region B1. In the fourth turn portion 124 corresponding to the inner turn portion and the fifth turn portion 125 corresponding to the outer turn portion, for example, the first straight portion 1314 and the first straight portion 1315 are radially adjacent to each other. The second straight portion 1334 and the second straight portion 1335 are radially adjacent to each other. Also, in the illustrated example, the first straight portion 1314 and the first straight portion 1315 are parallel, and the second straight portion 1334 and the second straight portion 1335 are parallel. The distance between one end and the other end, which are both ends of the first corner portion 1325 of the radially outer turn portion 125 of the two turn portions, is the same as the radially inner portion of the two turn portions. It is smaller than the distance between one end and the other end, which are both ends of the first corner portion 1324 of the turn portion 124 on the other side. More specifically, the curvature of first corner portion 1324 of radially inner turn 124 is less than the curvature of first corner portion 1325 of radially outer turn 125 .

According to the aspect described above, the distance between the radially outward first straight portion 1315 and the radially inward first corner portion 1324 gradually separates toward the midpoint side of the first corner portion 1324 . It extends like this. Similarly, the radially outer second straight portion 1335 and the radially inner first corner portion 1324 extend away gradually toward the midpoint of the first corner portion 1324 . In this case, the distance between the radially inner first corner portion 1324 and the radially outer first corner portion 1325 is, for example, the distance between the first straight portion 1314 and the first straight portion 1315. longer than As a result, the distance between the radially inner first corner portion 1324 and the radially outer first corner portion 1325 is partially increased. The first region B1 is formed between the radially inner first corner portion 1324 and the radially outer first corner portion 1325 . Also, the second region B2 is formed between the first linear portion 1314 and the first linear portion 1315, for example.

In this example, the gap between the fourth turn portion 124 and the fifth turn portion 125 includes four second regions B1. Specifically, in addition to the first region B1 between the radially inner first corner portion 1324 and the radially outer first corner portion 1325, the second corner portion 1344 and the second corner portion 1345 a first region B1 between, a first region B1 between the third corner portion 1364 and the third corner portion 1365, and a first region B1 between the fourth corner portion 1384 and the fourth corner portion 1385; , is formed. Second struts 32 of the struts 30, which will be described later, pass through each of the first regions B1. The first region B1 and the second region B2 may be formed between pairs of turn portions 12 n other than the pair of the fourth turn portion 124 and the fifth turn portion 125 .

Also, in the conductor 11E, the width of the gap between a certain pair of adjacent turn portions 12n is constant, but the size is different from the constant gap between other pairs of adjacent turn portions 12n. There is

Specifically, among the first to fourth turn portions 121 to 124 from the radially inner side of the coil 11, the gaps between all pairs of adjacent turn portions 12n are constant. be. Further, among the five turn portions 125 to 129 from the fifth to ninth radially inner sides of the coil 11, the gaps between all pairs of adjacent turn portions 12n are constant. However, the gap between pairs of adjacent turn portions 12n having a constant size between the five turn portions 125 to 129 from the fifth to ninth radially inward is It is smaller than the gap between pairs of adjacent turn portions 12n, which is a constant size between the four turn portions 121 to 124 from the first to the fourth.

That is, in the present embodiment, the gap between the adjacent turn portions 12n existing at a position larger than the value obtained by dividing the number of turns n of the coil 11 by 2 is located at a position smaller than the value obtained by dividing the number of turns n by 2. It is smaller than the gap between the existing adjacent turn portions 12n. The size of the gap is determined by determining the total area of the gaps between all pairs of adjacent turn portions 12n existing at a position larger than the value obtained by dividing the number of turns n by 2. and the value obtained by dividing the number of turns n by 2. This may be done by comparing the value divided by the total length.

As an example, the coil 11 described above is formed by punching a copper plate into a spiral shape. On the other hand, the coil 11 can also be formed by etching a copper foil into a spiral shape. In this case, the coil 11 can be formed in a complicated spiral pattern. However, etching requires a lot of time and effort to secure the thickness of the coil 11 that can transmit a large amount of power. Therefore, punching is preferable from the viewpoint of manufacturing efficiency.

Also, the thickness of the conductor 11E in the coil 11, in other words, the thickness of the turn portion 12n may be, for example, 0.2 mm or more and 1.0 mm or less. Also, the radius of the coil 11 (the distance from the center axis C to the most distant portion in the radial direction) may be 200 mm or more. When power is transmitted to an electric vehicle by the magnetic resonance method, it is desirable to be able to transmit power of 1 Kw or more, preferably 5 Kw or more in a high frequency current frequency range of 10 KHz to 200 KHz, particularly 79 KHz to 90 KHz. In this case, the thickness of the coil 11 made of copper is preferably 0.4 mm or more. In addition, if the thickness of the coil 11 is too large, the weight increases, which is not preferable for vehicle-mounted use, for example. Therefore, the thickness of the coil 11 may be, for example, 2.0 mm or less, 1.5 mm or less, or 1.0 mm or less.

The line width of the conductor 11E in the coil 11 is not particularly limited. However, considering that power of 1 Kw or more, preferably 5 Kw or more can be transmitted in a high frequency current frequency range of 79 kHz to 90 kHz, for example, the line width of the turn portion 12n may be 2 mm or more and 20 mm or less, or 2 mm or more. It may be 16 mm or less, 2 mm or more and 12 mm or less, or 2 mm or more and 8 mm or less. The line width means the distance between the inner peripheral surface and the outer peripheral surface of the conductor 11E in a cross section perpendicular to the direction in which the conductor 11E rotates.

(Case)
The case 20 has the bottom wall portion 22, the side wall portion 23, and the top wall portion 24 as described above. The bottom wall portion 22 is plate-shaped. The side wall portion 23 rises from the peripheral portion of the bottom wall portion 22 and is positioned on the outer circumference of the coil 11 . Side wall portion 23 surrounds coil 11 , support 30 , spacer member 40 , magnetic shield member 44 and insulating member 46 . The top wall portion 24 is joined to the tip of the side wall portion 23 to close the side wall portion 23 .

The case 20 has a rectangular shape in plan view, and the bottom wall portion 22 and the top wall portion 24 also have a rectangular shape in plan view. The side wall portion 23 has a rectangular frame shape in plan view. However, the shape of the case 20 in plan view is not particularly limited, and other shapes such as a circle may be used. 10 A of coil components may be incorporated in the power transmission apparatus installed, for example on a road surface. In the power transmission device installed on the road surface, it is assumed that the vehicle rides on the power transmission device. In this case, the top wall portion 24 covers and protects the coil 11 from above.

In this embodiment, as an example, the side wall portion 23 and the top wall portion 24 are integrally formed and made of the same material. The bottom wall portion 22 is formed separately from the side wall portion 23 and the top wall portion 24 . The bottom wall portion 22 may be made of a metal material and have electrical conductivity. Specifically, the bottom wall portion 22 is made of aluminum.

As described above, it is assumed that the coil component 10A is incorporated in a power transmission device installed on the road surface. In this case, it is preferable that the side wall portion 23 and the top wall portion 24 have high rigidity and strength. Therefore, the material of the side wall portion 23 and the top wall portion 24 may be fiber reinforced plastic or the like. Materials for the side wall portion 23 and the top wall portion 24 are not particularly limited. However, in the coil component 10A, it is assumed that the magnetism generated by the coil 11 or the magnetism from another coil is transmitted and received through the top wall portion 24 . Therefore, as a material for forming the top wall portion 24, a material that does not block magnetism is selected. Top wall 24 preferably has high stiffness and strength, and is preferably non-conductive (insulating) and non-magnetic. Considering these points, the material of the top wall portion 24 is preferably fiber reinforced plastic. Insulating means having a volume resistivity of 10 ¹⁰ Ω·m or more. Non-magnetic means not exhibiting magnetism.

The side wall portion 23 and the top wall portion 24 may be formed in one piece, for example by injection molding. Moreover, after the side wall portion 23 and the top wall portion 24 are separately formed, they may be joined together by welding or the like.

Bottom wall 22 may be made of a different material than top wall 24 and sidewalls 23 . The material of the bottom wall portion 22 may be an aluminum alloy, stainless steel, synthetic resin, or the like. When the bottom wall portion 22 is made of aluminum, an aluminum alloy, stainless steel, or the like, it also functions as a magnetic shield that prevents magnetic leakage to the outside. If the bottom wall portion 22 is made of synthetic resin such as fiber-reinforced plastic, it can be advantageous in terms of productivity and weight reduction. However, the material of the bottom wall portion 22 is not particularly limited.

The manner in which the bottom wall portion 22 is attached to the side wall portion 23 is not particularly limited. The bottom wall portion 22 may be detachably attached to the side wall portion 23 by fastening means such as screws and bolts. The bottom wall portion 22 may be attached to the side wall portion 23 by welding, or may be attached by an adhesive.

(pillar)
The strut 30 extends in the axial direction of the coil 11 and passes through the coil 11 . The strut 30 is positioned so as to be sandwiched between the top wall portion 24 and the bottom wall portion 22 facing each other. In this embodiment, one end of the column 30 is connected to the inner surface of the top wall portion 24 and the other end of the column 30 is in contact with the bottom wall portion 22 .

As shown in FIG. 2, the strut 30 includes a first strut 31 positioned radially inward of the innermost turn portion 121 and passing through the coil 11, and a first strut 31 between the adjacent turn portions 12n. and a second strut 32 located in the gap and passing through the coil 11 . Specifically, the coil component 10A includes one first strut 31 and four second struts 32 . However, the number of struts 30 is not particularly limited.

The 1st support|pillar 31 is a rectangular shape by planar view. Four corner portions of the first support 31 are chamfered in an arc shape. The turn portion 121 includes a first straight portion 1311, a first corner portion 1321, a second straight portion 1331, a second corner portion 1341, a third straight portion 1351, a third corner portion 1361, a fourth straight portion 1371, and a fourth corner. A rectangular shape is formed by connecting the portion 1381 and the fifth straight portion 1391 in this order. The rectangular shape of the first support 31 in plan view is parallel to the rectangular shape of the turn portion 121 in plan view.

Also, the four corner portions of the first post 31 face the first corner portion 1321, the second corner portion 1341, the third corner portion 1361, and the fourth corner portion 1381, respectively. With such a layout, the first struts 31 are provided radially inward of the innermost turn portion 121 with good space efficiency. Thereby, the cross-sectional area of the 1st support|pillar 31 can be ensured as large as possible.

The shape of the first strut 31 is not particularly limited, and may be, for example, a columnar shape or an elliptical columnar shape. When the first strut 31 has a columnar shape, it is preferable that the turn portion 121 has a circular planar shape. When the first strut 31 has an elliptical cylindrical shape, the shape of the turn portion 121 in plan view is preferably an ellipse.

The second strut 32 passes through each of the above-described four first regions B1 in the gap between the fourth turn portion 124 and the fifth turn portion 125. As shown in FIG. In the range from the second turn portion 122 from the radially inner side of the coil 11 to the second turn portion 128 from the radially outer side of the coil 11, the second strut 32 extends between the adjacent turn portions 12n. It is preferred to pass through the interstices. However, the position of the second support 32 is not particularly limited. In this embodiment, the second strut 32 is passed through only the gap between the fourth turn portion 124 and the fifth turn portion 125, but the second strut passed through the gap between the other turn portions 32 may be provided.

The four second struts 32 are provided at positions where the distances from the center axis C are the same. The case 20 has a rectangular shape when viewed in the axial direction of the coil 11 . In this case, the second struts 32 are preferably positioned on the diagonal line of the case 20 when viewed in the axial direction of the coil 11 . Alternatively, when viewed in the axial direction of the coil 11, the second strut 32 is sandwiched between two line segments extending at a position where the diagonal line of the case 20 is rotated ±10 degrees, preferably ±5 degrees around the center of the case 20. It is preferably located within the range of In this embodiment, the second strut 32 is provided in the latter relationship.

In this embodiment, the central axis C of the spiral shape described above is determined as follows. First, from the radially inner end of the innermost turn portion 121, a linear imaginary turn portion similar in shape to the innermost turn portion 121 is formed radially inward to form a spiral shape. Draw sequentially. Drawing is continued until a virtual turn portion within a diameter of 1 cm can be drawn. A center axis C is defined as a line passing through the radially inner side of the imaginary turn portion within a diameter of 1 cm in a direction orthogonal to the circumferential direction and the radial direction of the spiral shape.

The first region B1 is a region that is partially enlarged in the gap between the fourth turn portion 124 and the fifth turn portion 125 as described above. When the second support 32 is passed through the first area B1, the size of the second support 32 can be increased. On the other hand, the second region B2 in the gap between the fourth turn portion 124 and the fifth turn portion 125 is smaller than the first region B1. This suppresses reduction in the area of the conductor 11E. Therefore, deterioration of the coil characteristics due to the influence of the struts is suppressed.

Although the second support 32 in the present embodiment has a cylindrical shape, the shape of the second support 32 is not particularly limited. The second strut 32 may have a prismatic shape or an elliptical columnar shape. The second strut 32 may be columnar with a triangular, semicircular, crescent, fan-shaped, or the like cross-sectional shape.

Since the first strut 31 and the second strut 32 pass through the coil 11 , they are preferably made of a material that has little or no effect on the magnetism generated by the coil 11 . Specifically, the first support 31 and the second support 32 preferably have high rigidity and strength, and are preferably non-conductive (insulating) and non-magnetic. Considering this point, the material of the first struts 31 and the second struts 32 may be fiber reinforced plastic. However, the material of the first support 31 and the second support 32 is not particularly limited.

Also, the first strut 31 and the second strut 32 are integrally connected to the top wall portion 24 . In this embodiment, the first strut 31 and the second strut 32 and the top wall portion 24 are integrally molded. Note that the first support column 31 and the second support column 32 and the top wall portion 24 may be formed separately and then joined by welding or the like. Also, the first support 31 and the second support 32 may be integrally connected to the bottom wall portion 22 . Also, the first support 31 and the second support 32 may be separated from the case 20 , and in this case, they may be held in a state of being sandwiched between the bottom wall 22 and the top wall 24 .

Further, the size of the first strut 31 in plan view may be 10% or less of the area of the coil 11 in plan view. The size of each second strut 32 in plan view may be 2.5% or less of the area of the coil 11 in plan view. The area of the coil 11 in plan view referred to here is the area of a range surrounded by a closed shape in which the outer peripheral side end portion 11B of the coil 11 is connected to the outermost turn portion 129 at the shortest distance.

(Spacer member)
The spacer member 40 is arranged so as to overlap the bottom wall portion 22 . The spacer member 40 is a member that supports the coil 11 at a position separated from the bottom wall portion 22 . The spacer member 40 in this embodiment supports the coil 11 via the magnetic shield member 44 and the insulating member 46 . The spacer member 40 is in contact with the bottom wall portion 22 and the magnetic shield member 44 .

The illustrated spacer member 40 is sheet-like or plate-like. A part such as a capacitor used when configuring the power transmission device may be arranged in a portion of the bottom wall portion 22 where the spacer member 40 does not exist. However, the shape of the spacer member 40 is not particularly limited.

Moreover, the material of the spacer member 40 is not particularly limited. The spacer member 40 may be made of metal or resin, for example.

(Magnetic shield member)
The magnetic shield member 44 is provided to suppress magnetic transmission and/or leakage magnetic field. The magnetic shield member 44 is sheet-shaped and is formed in a size that includes the insulating member 46 and the coil 11 in plan view. The magnetic shield member 44 is formed with a through-hole for allowing the column 30 to pass therethrough. The through-holes formed in the magnetic shield member 44 overlap with the radially inner side of the innermost turn portion 121 of the coil 11 and each first region B1 formed in the coil 11 .

The magnetic shield member 44 contains a magnetic material. The magnetic field generated by the coil component 10A is generated so as to spread in all directions with respect to the center axis C of the coil 11. As shown in FIG. At this time, since the magnetic shield member 44 has magnetism, it is possible to orient the expanding magnetic flux lines toward the center axis C side. Further, if the magnetic field generated by the coil component 10A flows toward other peripheral components, the peripheral components may be adversely affected. Therefore, the magnetic shield member 44 is provided to suppress transmission of the lines of magnetic force. Thereby, the magnetic shield member 44 can suppress leakage magnetic fields that do not contribute to current generation.

The magnetic shield member 44 preferably contains a soft magnetic material. More specifically, the magnetic shield member 44 contains ferrite, preferably soft ferrite. The magnetic shield member 44 may also include a nanocrystalline magnetic material.

(insulating member)
The insulating member 46 overlaps the coil 11 in the axial direction of the coil 11 . In this state, the insulating member 46 is integrated with the coil 11 . The insulating member 46 has a sheet shape and is formed in a size that includes the coil 11 in a plan view.

As shown in FIGS. 3 to 5, the insulating member 46 has a spiral recess 46g corresponding to the spiral shape of the coil 11. As shown in FIGS. The recess 46 g has a spiral shape when viewed in the axial direction of the coil 11 and is recessed in the axial direction of the coil 11 , in other words, in the thickness direction of the insulating member 46 . At least part of the coil 11 is accommodated in the recess 46g with its spiral shape aligned with the spiral shape of the recess 46g. Specifically, the recess 46g accommodates the entire conductor 11E.

In this embodiment, the conductor 11E is flush with the insulating member 46 without protruding from the recess 46g. However, part of the coil 11 may be housed in the recess 46g so that part of the coil 11 protrudes from the recess 46g. Alternatively, the coil 11 may be provided on the flat surface of the insulating member 46 without forming the concave portion 46 g in the insulating member 46 . Alternatively, the conductor 11E may be embedded in the insulating member 46 without being exposed to the outside.

The insulating member 46 is welded to the coil 11 at the recess 46g. That is, the coil 11 and the recess 46g are joined by an anchor effect. The coil 11 and the insulating member 46 are integrated by heat pressing, for example. At this time, part of the insulating member 46 enters the recesses on the surface of the coil 11 and is then hardened. As a result, the coil 11 and the recess 46g are welded together, and the insulating member 46 and the coil 11 are integrated.

In this embodiment, the insulating member 46 contains glass fiber-filled epoxy resin. That is, the insulating member 46 is made of a material containing epoxy resin as a thermosetting resin (thermosetting material) and glass fiber. When the coil 11 and the insulating member 46 are integrated by hot pressing, the coil 11 is pushed into the material forming the insulating member 46 to form the spiral recess 46g. At this time, if the material for forming the insulating member 46 is an epoxy resin containing glass fiber, the epoxy resin softens and flows along the side surface of the coil 11 to form the recess 46g. At this time, the glass fiber suppresses excessive flow of the epoxy resin.

In view of the above, it is preferable that the insulating member 46 and its forming material be epoxy resin containing glass fiber. However, the insulating member 46 and its forming material are not particularly limited. For example, it may contain no glass fibers. Also, instead of glass fiber, carbon fiber or the like may be used. Also, instead of epoxy resin, polyimide (thermoplastic resin) may be used.

4 and 5, the insulating member 46 is formed with a through hole 46t for allowing the support 30 to pass therethrough. The through hole 46 t formed in the insulating member 46 overlaps with the radially inner side of the innermost turn portion 121 of the coil 11 and each first region B 1 formed in the coil 11 . Specifically, the through hole 46t includes a first through hole 46t1 that overlaps radially inwardly of the turn portion 121, and a second through hole 46t2 that overlaps the first region B1. The first through hole 46t1 has a rectangular shape in plan view. The second through hole 46t2 is circular. The holes formed in the magnetic shield member 44 may have the same shape as the corresponding through holes 46t.

Also, as shown in FIG. 3, the insulating member 46 and the coil 11 integrated with the insulating member 46 are separated from the inner surface of the top wall portion 24 of the case 20 . As a result, the load received by the top wall portion 24 is suppressed from being transmitted to the coil 11, and the coil 11 can be protected. However, the coil 11 and/or the insulating member 46 may contact the inner surface of the top wall portion 24 .

(Connecting terminal)
As shown in FIG. 2, the first connection terminal 51 is connected to the inner peripheral side end portion 11A of the coil 11 . The second connection terminal 52 is connected to the outer peripheral end portion 11B of the coil 11 . In the present embodiment, the lead portion connected to the radially inner end portion of the turn portion 121 of the conductor 11E forms the inner peripheral end portion 11A of the coil 11 . The lead portion connected to the radially outer end portion of the turn portion 129 forms the outer peripheral end portion 11B of the coil 11 . The first connection terminal 51 and the second connection terminal 52 can be used, for example, when connecting with the high-frequency current supply section 1A or the conversion section 2A. The connection between the first connection terminal 51 and the inner peripheral side end portion 11A and the connection between the second connection terminal 52 and the outer peripheral side end portion 11B are performed by ultrasonic bonding. However, the connection method is not limited, and connection using a conductive adhesive may be employed, for example.

(Use of coil parts)
The coil component 10A according to the present embodiment can be used, for example, as a power transmitting coil in the power transmitting device 1 of the wireless power transmission system S described above, and can be used as a power receiving coil in the power receiving device 2 .

When the coil component 10A is used as the power transmission coil, the first connection terminal 51 and the second connection terminal 52 are connected to the high frequency current supply section 1A or AC power supply as shown in FIG. When a high frequency current is supplied to the coil component 10A, the current can be supplied from the first connection terminal 51 to the coil 11 and then from the second connection terminal 52 to the high frequency current supply section 1A or the AC power supply. In addition, after the current is supplied from the second connection terminal 52 to the coil 11, the current can be supplied from the first connection terminal 51 to the high-frequency current supply section 1A or the AC power supply. Thereby, a magnetic field including magnetic lines of force along the central axis of the coil 11 can be generated.

On the other hand, when the coil component 10A is used as the power receiving coil, the coil 11 can generate a high-frequency current by receiving a magnetic field including magnetic lines of force along the central axis of the coil 11 . Then, this high-frequency current can be supplied from the first connection terminal 51 or the second connection terminal 52 to an external device.

(action/effect)
The coil component 10A described above includes a coil 11, a case 20 that is a housing member that houses the coil 11, and one or more struts 30 that extend in the axial direction of the coil 11 and pass through the coil 11. . The coil 11 includes a spiral-shaped conductor 11E, and the conductor 11E includes a plurality of turn portions 12n arranged radially outward from the central axis C of the spiral. At least one of both end portions of the support 30 is connected to the inner surface of the case 20, contacts the inner surface of the case 20, or is separated from the inner surface of the case 20 and faces the inner surface. In this embodiment, one end of the support 30 is connected to the inner surface of the top wall 24 .

In this configuration, the load received by the case 20 can be supported by the struts 30, so that the strength of the coil component 10A is improved as compared with the case where the load is borne by the case 20 alone. In addition, since the strut 30 is provided so as to pass through the coil 11 , restrictions on the coil size are alleviated compared to the case where a load-bearing member such as a strut is provided radially outward of the coil 11 . As a result, a decrease in coil area due to the influence of the struts 30 is suppressed, so deterioration of the coil characteristics can be suppressed. Therefore, good strength and good coil characteristics can be ensured.

In addition, the strut 30 includes a first strut 31 positioned radially inward of the innermost turn portion 121 . In this configuration, a relatively large space radially inward of the innermost turn portion 121 can be utilized to provide the large-sized first strut 31 . Thereby, the strength of the coil component 10A can be effectively improved.

The support 30 also includes a second support 32 passing between the adjacent turn portions 12n. In this configuration, by utilizing the gaps between the turn portions 12n to provide the second struts 32, the influence of the second struts 32 on the coil characteristics can be suppressed. As a result, the strength of the coil component 10A can be effectively improved while ensuring good coil characteristics.

In addition, the second strut 32 is preferably positioned between the second radially inner turn portion 122 of the coil 11 and the second radially outer turn portion 128 of the coil 11 . . In the present embodiment, the second strut 32 is positioned between the fourth turn portion 124 and the fifth turn portion 125 from the radially inner side of the coil 11 . With this configuration, it is possible to prevent the second struts 32 from being biased toward the inner side or the outer side in the radial direction of the coil. As a result, local reduction in strength and rigidity of the coil component 10A can be suppressed, so that the strength of the coil component 10A can be effectively improved.

In addition, the gap between the adjacent turn portions 124 and 125 through which the second support 32 passes is larger than the width of the first region B1 through which the second support 32 passes in the radial direction of the first region B1. and a narrow second region B2. In this configuration, by making the first region B1 larger than the second region B2, the area of the second pillar 32 can be secured as large as possible. Further, by narrowing the second region B2, reduction in the area of the coil 11 can be suppressed. As a result, good coil characteristics can be ensured while effectively improving the strength of the coil component 10A.

In addition, in the turn portion 124 corresponding to the inner turn portion and the turn portion 125 corresponding to the outer turn portion adjacent to each other forming the gap through which the second strut 32 passes, the first straight portion 1314 and the first straight portion 1315 are radially adjacent to each other, and the second linear portion 1334 and the second linear portion 1335 are radially adjacent to each other. The distance between one end and the other end, which are both ends of the first corner portion 1325 of the radially outer turn portion 125 of the two turn portions, is the same as the radially inner portion of the two turn portions. It is smaller than the distance between one end and the other end, which are both ends of the first corner portion 1324 of the turn portion 124 on the other side. Thereby, the first region B1 is formed between the first corner portion 1324 of the turn portion 124 corresponding to the inner turn portion and the first corner portion 1325 of the turn portion 125 corresponding to the outer turn portion. .

In this configuration, the first region B1 through which the second support 32 passes can be made larger than the second region B2 while suppressing abrupt shape change in the turn portion 12n to suppress electrical resistance. This is extremely advantageous in ensuring good strength and good coil characteristics. In this embodiment, the radially adjacent first corner portions 1324 and 1325 are arc-shaped, and the curvature of the radially inner first corner portion 1324 is greater than the curvature of the outer first corner portion 1325 . is also small. In this case, the first region B1 through which the second support column 32 passes can be made larger than the second region B2 while suppressing the electrical resistance by suppressing abrupt shape changes in the turn portions 124 and 125 in a simple form. Therefore, it is extremely advantageous in ensuring productivity, good strength, and good coil characteristics.

Further, when viewed in the axial direction of the coil 11, the case 20 has a rectangular shape. When viewed in the axial direction of the coil 11, the second strut 32 is positioned on the diagonal line of the case 20, or is a line segment extending at a position obtained by rotating the diagonal line of the case 20 by ±10 degrees around the center of the case 20. located within the range between In this configuration, for example, the second strut 32 cooperates with the first strut 31 of the coil 11 and the case 20 to bear the load received by the case 20, so that the desired strength can be secured while suppressing the number of struts 30. . This is advantageous in ensuring good strength.

Moreover, the coil component 10A further includes an insulating member 46 that contacts the coil 11 in the axial direction of the coil 11 . The insulating member 46 is formed with a through-hole that overlaps the gap between the adjacent turn portions 124 and 125 through which the second struts 32 pass. Then, the second strut 32 passes through the through hole in the insulating member 46 and the gap between the adjacent turn portions 124 and 125 . In this configuration, while the insulating member 46 reinforces and suppresses deformation of the coil 11 , the support 30 can improve the strength of the entire coil component 10A.

Also, the coil 11 is separated from the inner surface of the case 20 to which the strut 30 is connected, touches or faces. With this configuration, it is possible to suppress the load from being transmitted from the inner surface of the case 20 to the coil 11 and protect the coil 11 . Further, in this embodiment, the strut 30 is connected to the inner surface of the case 20 . In this configuration, by integrating the case 20 and the strut 30, the handleability is improved and high strength can be easily secured. Further, the case 20 has a side wall portion 23 surrounding the outer periphery of the coil 11 and a top wall portion 24 corresponding to an end wall closing the side wall portion 23 . The strut 30 is integrally connected to the top wall portion 24 . In this configuration, the support 30 and the side wall portion 23 can bear the load from the top wall portion 24 . Therefore, the strength of the coil component 10A can be effectively improved.

<Second Embodiment>
Next, a coil component 10B according to a second embodiment will be described. FIG. 6 is a perspective view of the coil component 10B. FIG. 7 is a perspective view of the coil 11 and the insulating member 46 that constitute the coil component 10B. The same reference numerals are assigned to the same components in the present embodiment as those in the first embodiment, and duplicate descriptions will be omitted.

As shown in FIGS. 6 and 7, coil component 10B in the present embodiment includes two types of second struts 32, 32'. The second strut 32 of the two types of second struts 32, 32' has the same configuration as described in the first embodiment. On the other hand, the second strut 32 ′ passes through the coil 11 at a different position than the second strut 32 .

The second struts 32' pass between adjacent radially inner straight portions and radially outer straight portions of the radially adjacent turn portions 12n. As shown in FIG. 7, the insulating member 46 is formed with a third through hole 46t3 for passing the second support 32'.

More specifically, the second struts 32' pass between adjacent straight portions of the plurality of adjacent turn portions 12n. In the present embodiment, referring also to FIG. 5, all eight pairs of radially adjacent turn portions 12n from the first to ninth radially inner turn portions 12n Between the first straight portion 131n and the radially outer first straight portion 131n, between the radially inner second straight portion 133n and the radially outer second straight portion 133n, the radial Between the inner third straight portion 135n and the radially outer third straight portion 135n, between the radially inner fourth straight portion 137n and the radially outer fourth straight portion 137n , the second strut 32' passes. The shape of the second strut 32' in plan view is a rectangular shape extending along corresponding straight line portions.

8 to 10 are diagrams for explaining the method of manufacturing the coil component 10B. In this example, first, as shown in FIG. 8, a coil intermediate 11M is prepared. The coil intermediate body 11M has a shape in which a plurality of connecting portions 11C are provided on the coil 11, or more precisely, on the conductor 11E. The connecting portion 11C shown in the figure connects the radially adjacent turn portions 12n of the conductor 11E. When the spiral-shaped coil 11 itself is formed by punching, the coil 11 is likely to be deformed. 11 C of connection parts are provided in order to maintain the shape of the coil 11. As shown in FIG.

Next, as shown in FIG. 9, the coil intermediate 11M and the insulating member intermediate 46M are integrated. The coil intermediate 11M and the insulating member intermediate 46M may be integrated by hot pressing. The insulating member intermediate 46M corresponds to the insulating member 46 before the through holes 46t are formed. The material for forming the insulating member intermediate 46M may be a material containing epoxy resin as a thermosetting resin (thermosetting material) and glass fiber. When hot pressing is performed, the sheet-like insulating member intermediate 46M forming material and the coil intermediate 11M may be overlapped. Then, the material for forming the insulating member intermediate 46M and the coil intermediate 11M may be heated while being pressed by a mold or a press.

Next, as shown in FIG. 10, the connecting portion 11C is removed. At this time, the connecting portion 11C is removed in the axial direction of the conductor 11E together with a part of the insulating member intermediate 46M. Coil 11 is formed by removing connecting portion 11C. A first through hole 46t1, a second through hole 46t2, and a third through hole 46t3 are formed in the insulating member intermediate 46M. Thereby, the insulating member 46 is formed. The third through hole 46t3 is formed in a region including the portion corresponding to the connecting portion 11C in the insulating member intermediate 46M. The third through hole 46t3 is formed to have a size larger than that of the connecting portion 11C. The third through-hole 46t3 elongates along between the straight portions of the adjacent turn portions 12n. Thereby, a large size of the second strut 32' can be ensured.

That is, the third through hole 46t3 is a hole formed when removing the connecting portion 11C. In the present embodiment, the third through holes 46t3 formed due to the manufacturing process are used as holes through which the second struts 32' pass.

In the second embodiment described above, the number of struts 30 is increased, so the strength of coil component 10B is improved. Further, by arranging the second struts 32' between the straight portions of the adjacent turn portions 12n, the length of the second struts 32' can be easily increased, and the shape of the second struts 32' can be simplified. . As a result, it is advantageous in terms of securing good strength while suppressing the time and effort required to manufacture the strut.

Further, the third through hole 46t3 in the insulating member 46 through which the second support column 32' is passed is a hole formed when the connecting portion 11C is removed. Therefore, the strength of the coil component 10B can be improved by effectively utilizing the holes formed due to the manufacturing process. If the second support 32' is not arranged in the third through hole 46t3, the strength of the insulating member 46 may be improved by filling the third through hole 46t3.

<Third Embodiment>
Next, a coil component 10C according to a third embodiment will be described. FIG. 11 is a perspective view of the coil component 10C. FIG. 12 is a perspective view of the coil 11 and the insulating member 46 that constitute the coil component 10C. The same reference numerals are assigned to the same components in the present embodiment as those in the first and second embodiments, and duplicate descriptions will be omitted.

As shown in FIGS. 11 and 12, the coil component 10C in this embodiment includes a first support 31 and four second supports 32. As shown in FIGS. The positions and numbers of the first struts 31 and the second struts 32 are the same as in the first embodiment. On the other hand, the shape of the second strut 32 is different from that of the first embodiment.

Specifically, the second strut 32 in the present embodiment is formed in a semicircular shape in plan view. That is, the second strut 32 is formed as a columnar body having a semicircular cross-sectional shape in the cross section. The arc surface of the second strut 32 faces the radially outer corner portion of the adjacent turn portions 12n. The third through hole 46t3 in the insulating member 46 is also formed in a semicircular shape in plan view. The third through hole 46t3 overlaps the first region B1.

In the present embodiment, the second struts 32 are formed in a semicircular shape in plan view, which makes it easier to increase the size of the second struts 32 passing through the first region B1. This is advantageous in ensuring good strength in the coil component 10C.

<Fourth Embodiment>
Next, a coil component 10D according to a fourth embodiment will be described. FIG. 13 is a perspective view of the coil component 10D. FIG. 14 is a perspective view of the coil 11 and the insulating member 46 that constitute the coil component 10D. The same components as those in the first to third embodiments among the components in the present embodiment are denoted by the same reference numerals, and overlapping descriptions are omitted.

As shown in FIGS. 13 and 14, a coil component 10D according to the present embodiment includes a first strut 31 similar to that of the first embodiment and a plurality of second struts 32 described in the second embodiment. ' and prepare. On the other hand, the second support 32 is not arranged in the first region B1 of the coil 11 .

In the present embodiment, by reducing the number of through holes 46t in the insulating member 46, it is advantageous in ensuring the strength of the insulating member 46. FIG. Note that the first region B1 may not be formed in the coil 11 .

<Fifth Embodiment>
Next, a coil component 10E according to a fifth embodiment will be described. FIG. 15 is a cross-sectional view of the coil component 10E. The same components as those in the first to fourth embodiments among the components in the present embodiment are denoted by the same reference numerals, and overlapping descriptions are omitted.

As shown in FIG. 15, in coil component 10E according to the present embodiment, conductor 11E of coil 11 is embedded in insulating member 46 so as not to be exposed to the outside. With such a configuration, warping of the coil 11 can be effectively suppressed.

<Sixth Embodiment>
Next, a coil component 10F according to the sixth embodiment will be described. FIG. 16 is a cross-sectional view of the coil component 10F. The first of the components in this embodiment

As shown in FIG. 16, in coil component 10F according to the present embodiment, coil 11 includes a first coil 11-1 and a second coil 11-2. The insulating member 46 has a three-layer structure and includes a first insulating member 46-1, a second insulating member 46-2, and a third insulating member 46-3. The first coil 11-1, the second coil 11-2, the first insulating member 46-1, the second insulating member 46-2, and the third insulating member 46-3 are integrated. . The conductor 11E included in each of the first coil 11-1 and the second coil 11-2 is embedded in the insulating member 46 (46-1 to 46-3) so as not to be exposed to the outside. The first coil 11-1 and the second coil 11-2 overlap each other in the axial direction and are held apart from each other in the axial direction. The first coil 11-1, more precisely its conductor 11E, is sandwiched between the first insulating member 46-1 and the second insulating member 46-2. The second coil 11-2, more precisely its conductor 11E, is sandwiched between the second insulating member 46-2 and the third insulating member 46-3. Also, the first insulating member 46-1 is in contact with the magnetic shield member 44. As shown in FIG.

The first coil 11-1 and the second coil 11-2 may be connected in series or in parallel. In FIG. 16, the boundary between the first insulating member 46-1 and the second insulating member 46-2 is shown near the midpoint in the thickness direction of the first coil 11-1. A boundary between the second insulating member 46-2 and the third insulating member 46-3 is shown near the midpoint in the thickness direction of the second coil 11-2. These boundaries may not appear in appearance when the first insulating member 46-1, the second insulating member 46-2 and the third insulating member 46-3 are integrated. clearly indicated for

In the above configuration, the first coil 11-1, the second coil 11-2, the first insulating member 46-1, the second insulating member 46-2, and the third insulating member 46-3 It is possible to effectively suppress warpage that may occur in an integrated product. Moreover, the amount of heat generated per unit area of the coil can be suppressed by increasing the total amount of the coil.

<Evaluation of Coil Characteristics>
Next, evaluation results of the coil characteristics of the coil component 10A according to the first embodiment and the coil characteristics of the coil component according to the comparative example will be described. In the evaluation, a high frequency current of 85 Hz was supplied to each coil component, and the inductance Ls and impedance Rs at that time were measured. Then, the Q value was calculated from the measured Ls and Rs.

In the coil component 10A according to the first embodiment, the gap between the fourth turn portion 124 and the fifth turn portion 125 from the radially inner side of the coil 11 is partially formed in the first region B1. grow to In the comparative example, the shape of the first to fourth turn portions from the inside in the radial direction of the coil is the same as that of the coil component 10A. On the other hand, the width of the gap between the fourth turn portion and the fifth turn portion is constant. In the comparative example, each turn forms a spiral shape from the first turn to the ninth turn while the width of the gap between the turns is kept constant. The evaluation results are as shown in Table 1 below.

The inductance Ls of the coil component 10A according to this embodiment is lower than that of the comparative example. This is probably because the area of the coil 11 is smaller than that of the comparative example. On the other hand, the impedance Rs of the coil component 10A is lower than that of the comparative example. It is considered that this is because the increase in resistance due to the proximity effect is suppressed in this embodiment. Then, when the Q value is compared, it can be evaluated that there is no difference between the two. From these results, it was presumed that, in the present embodiment, the gaps between the turn portions 12n widened for the struts 30 contribute to suppressing the increase in resistance due to the proximity effect. Thus, it was presumed that the support 30 could improve the strength of the coil component 10A while suppressing deterioration of the coil characteristics.

Although the embodiments of the present disclosure have been described above, various modifications may be made to the above-described embodiments. Such modifications may also be included in the technical scope of the present disclosure.

S Power transmission system 1 Power transmission device 1A High-frequency current supply unit 2 Power reception device 2A Conversion units 10, 10A, 10B, 10C, 10D, 10E, 10F Coil component 11 Coil 11A Inner peripheral end 11B Outer peripheral side end portion 11C Connecting portion 11E Conductor 11M Intermediate coil bodies 12n, 121, 122, 128, 129 Turn portion 131n First straight portion 132n First corner portion 133n Second second Straight portion 134n Second corner portion 135n Third straight portion 136n Third corner portion 137n Fourth straight portion 138n Fourth corner portion 139n Fifth straight portion 20 Case 22 Bottom wall 23 Side wall 24... Top wall portion 30... Support 31... First support 32, 32'... Second support 40... Spacer member 44... Magnetic shield member 46... Insulating member 46g... Recess 46t1... First through hole 46t2... Second through hole 46t3 ...third through hole 46M...insulating member intermediate body 51...first connection terminal 52...second connection terminal

Claims (19)

a coil comprising a conductor having a spiral shape, the conductor including a plurality of turn portions arranged radially outward from a central axis of the spiral shape;
a storage member that stores the coil;
one or more struts extending axially of the coil and passing through the coil;
At least one of the ends of the strut is connected to the inner surface of the housing member, contacts the inner surface of the housing member, or faces the inner surface away from the inner surface of the housing member. 2. The coil component according to claim 1, wherein said one or more struts include a first strut located radially inward of said innermost turn portion. 3. The coil component according to claim 1, wherein the one or more struts include second struts passing between the radially adjacent turn portions. The second strut is positioned between the second radially inner turn portion of the coil and the second radially outer turn portion of the coil. 4. The coil component according to 3. The gap between the radially adjacent turn portions through which the second support passes is greater than the width of the first region through which the second support passes in the radial direction. 5. The coil component according to claim 3, comprising a second region having a narrow width at . An inner turn portion positioned radially inward and an outer turn portion positioned radially outward of the radially adjacent turn portions forming a gap through which the second strut passes. Each of has a first straight portion and a second straight portion extending along a straight line, and a corner portion connecting the first straight portion and the second straight portion,
The corner portion has an arc shape, a straight line shape, or a polygonal line shape along the arc, the first straight portion extends straight from one end of the corner portion, and the second straight portion extends beyond the corner portion. Extending straight from the end,
In the inner turn portion and the outer turn portion, the first straight portions are adjacent to each other in the radial direction, the second straight portions are adjacent to each other in the radial direction, and the corner portion of the outer turn portion is is smaller than the distance between both ends of the corner portion of the inner turn portion, and the first region is formed between the corner portion of the inner turn portion and the corner portion of the outer turn portion 6. The coil component according to claim 5, which is a region between and. The corner portion of the inner turn portion and the corner portion of the outer turn portion are arc-shaped, and the curvature of the corner portion of the inner turn portion is greater than the curvature of the corner portion of the outer turn portion. 7. The coil component according to claim 6, wherein the is also small. When viewed in the axial direction of the coil, the housing member has a rectangular shape,
When viewed in the axial direction of the coil, the second strut is positioned on the diagonal line of the storage member, or at a position where the diagonal line of the storage member is rotated ±10 degrees around the center of the storage member. 8. The coil component according to any one of claims 3 to 7, located within a range sandwiched by the extending line segments. An inner turn portion positioned radially inward and an outer turn portion positioned radially outward of the radially adjacent turn portions forming a gap through which the second strut passes. each of has a straight portion extending along a straight line,
5. The coil component according to claim 3, wherein said second strut passes between said straight portion of said inner turn portion and said straight portion of said outer turn portion which are adjacent to each other. further comprising an insulating member in contact with the coil in the axial direction of the coil;
A through hole is formed in the insulating member so as to overlap a gap between the radially adjacent turn portions through which the second strut passes,
5. The coil component according to claim 3, wherein said second strut passes through said through hole and said gap. An inner turn portion positioned radially inward and an outer turn portion positioned radially outward of the radially adjacent turn portions forming a gap through which the second strut passes. each of has a straight portion extending along a straight line,
11. The coil component according to claim 10, wherein said through hole overlaps said gap between said linear portion of said inner turn portion and said linear portion of said outer turn portion adjacent to each other. 12. The coil component according to any one of claims 1 to 11, wherein the coil is spaced apart from an inner surface of the housing member to which the strut is connected, touches or faces. The storage member has a side wall portion surrounding the outer periphery of the coil and an end wall portion closing the side wall portion,
13. The coil component according to any one of claims 1 to 12, wherein said strut is integrally connected to said end wall. 14. The storage member according to any one of claims 1 to 13, wherein the post is separate from the storage member, and is sandwiched between opposing portions on the inner surface of the storage member or sandwiched between the inner surface of the storage member and another member. The coil component according to any one of the above. 15. The coil component according to any one of claims 1 to 14, wherein said post is non-magnetic and insulating. A conductor having a spiral shape is provided,
The conductor includes a plurality of turn portions arranged radially outward from the central axis of the spiral shape,
The inner turn portion located radially inward and the outer turn portion located radially outward in at least one pair of the radially adjacent turn portions of the plurality of turn portions. Each of the square turn portions has a first straight portion and a second straight portion extending along a straight line, and a corner portion connecting the first straight portion and the second straight portion,
The corner portion has an arc shape, a straight line shape, or a polygonal line shape along the arc, the first straight portion extends straight from one end of the corner portion, and the second straight portion extends beyond the corner portion. Extending straight from the end,
In the inner turn portion and the outer turn portion, the first straight portions are adjacent to each other in the radial direction, the second straight portions are adjacent to each other in the radial direction, and the corner portion of the outer turn portion is is smaller than the distance between both ends of the corner portion of the inner turn portion, and the gap between the inner turn portion and the outer turn portion is the corner portion of the inner turn portion and the corner portion of the outer turn portion; and a second region having a width in the radial direction that is narrower than the width in the radial direction of the first region. A power transmitting device comprising the coil component according to any one of claims 1 to 15. A power receiving device comprising the coil component according to any one of claims 1 to 15. comprising a power transmitting device and a power receiving device,
A power transmission system, wherein at least one of the power transmission device and the power reception device comprises the coil component according to any one of claims 1 to 15.