JP3864094B2 - Contactless power supply coupler - Google Patents

Description

[0001]
BACKGROUND OF THE INVENTION
The present invention relates to a magnetic coupling type non-contact power feeding coupler, for example, to a technique effective when used for non-contact power feeding and charging to an electric vehicle or an electric device.
[0002]
[Prior art]
Magnetic coupling type non-contact power supply couplers are provided as means for performing non-contact power supply and charging to electric vehicles, electric bicycles, and other electric devices.
This non-contact power feeding coupler is composed of a primary side magnetic unit and a secondary side magnetic unit corresponding to a primary coil and a secondary coil of a transformer. By electrically coupling both units, an electrically non-contact state can be obtained. Transmission of alternating current (high frequency) power can be performed while maintaining. This type of power supply coupler can be expected to have advantages such as less risk of electric leakage and electric shock, and fewer failure factors such as poor contact. It is also effective for preventing sparks caused by spark sparks and is suitable for use in places where fire is strictly prohibited. For example, a non-contact type power supply coupler that has a low risk of ignition is suitable for supplying power to an electric vehicle at an existing gas station.
[0003]
[Problems to be solved by the invention]
As described above, the magnetic coupling type non-contact power feeding coupler is expected to have many merits. However, in order to transmit power by magnetic coupling, both the power feeding side and the power receiving side are each made of a magnet consisting of a coil and a magnetic core. A unit is needed. In addition, alignment means for correctly magnetically coupling both units is also required. For this reason, the non-contact power supply coupler has a problem that the configuration is complicated and tends to be large, and the handling thereof is not easy, unlike a normal contact power supply such as an outlet or a plug.
[0004]
Conventionally, magnetically coupled non-contact power feeding couplers have been put to practical use for extremely small power feeding, such as a charging base for a cordless telephone. However, there is no such thing as a part-time employee or customer at a gas station that can be easily operated and used in a relatively large power supply application such as charging an electric vehicle.
[0005]
In an electric vehicle, a large amount of power needs to be supplied in order to complete charging as quickly as possible. In order to perform this power supply using a non-contact power supply coupler, the magnetic units are installed on both the power supply side (charging station) and the power reception side (electric vehicle), but each unit corresponds to the required power supply. Must be of capacity scale.
[0006]
For the electric vehicle on the power receiving side, it is advantageous and reasonable in terms of manufacturing cost to divert the body of a general gasoline vehicle. In addition, in order to supply power to an electric vehicle at a stand like a general gasoline vehicle (a vehicle powered by an internal combustion engine including a diesel vehicle), the power receiving port that receives the power supply is the same location as the refueling port of a general gasoline vehicle It is reasonable to place
[0007]
When manufacturing an electric vehicle, it is economical and reasonable to divert the body structure and usage style of a gasoline-powered vehicle that has a technical tradition and a track record of use as much as possible. For this reason, it is desirable that the magnetic unit of the non-contact power feeding coupler fits in the fueling port of the gasoline vehicle. It is also desirable that the coupler and the charging device not be damaged even if the automobile is started with the magnetic unit removed. And even unskilled part-time employees and customers need to be able to operate easily and neatly.
[0008]
The present invention has been made in view of the background as described above, and is suitable for relatively large power supply, and can be made compact so that it can be accommodated in, for example, a fuel filler of an existing gasoline vehicle. Another object of the present invention is to provide a non-contact power feeding coupler that can be easily and skillfully operated even by a non-skilled person and hardly damaged even if misused.
[0009]
[Means for Solving the Problems]
The solution provided by the present invention is that the primary side magnetic unit and the secondary side magnetic unit each having a soft magnetic core and a coil are magnetically coupled so as to be detachable, so that they are not electrically connected from the primary side to the secondary side. A contactless power supply coupler configured to perform power transmission by contact, comprising the following constituent means (1) to ( 5 ).
[0010]
(1) The primary side core has a collar part and a column part, and the cross section is formed in a substantially T shape.
(2) A rod-shaped guide portion having a diameter smaller than that of the column portion is attached to the tip of the column portion so as to protrude coaxially.
(3) The secondary-side core is formed in a saddle shape and forms a closed magnetic circuit together with the primary-side core.
(4) The length of the said rod-shaped guide part is larger than the depth of the core of the secondary side formed in the said saddle shape.
(5) A guide hole for guiding the insertion of the rod-shaped guide portion is provided at the center of the bottom surface of the secondary-side core formed in the saddle shape.
[0011]
By the above means, it is suitable for power supply of relatively large power, and can be made compact so that it can be accommodated, for example, in the filling port of an existing gasoline vehicle, and can be easily and neatly operated even by an unskilled person. Thus, it is possible to provide a non-contact power feeding coupler that is not easily damaged even if misused. In addition, by making the length of the rod-shaped guide part larger than the depth of the secondary saddle-shaped core, the coil on the primary side is fixed until the guide part is inserted into the guide hole and guided. It can be separated from both the secondary core and coil, and the primary coil enters the secondary core when the guide and guide holes are in a reliable state. Therefore, when the primary side magnetic unit is attached to the secondary side magnetic unit, it is possible to reliably avoid the primary side coil from hitting the secondary side core or the secondary side coil.
[0012]
Furthermore, in order to further enhance the above effect, the present invention also provides the following means in relation to the above means.
That is, the collar portion is a disc shape, and the column portion is a column shape. The saddle-shaped core is cylindrical. Thereby, for example, an advantage that alignment in the rotation direction can be made unnecessary can be obtained.
[0013]
The primary coil is wound around the column portion. The secondary coil is wound along the inner surface of the saddle-shaped core. In order to prevent the occurrence of magnetic loss and eddy current loss, the rod-shaped guide portion is made nonmagnetic and nonconductive. A frame having a diameter larger than that of the collar is attached to the upper surface of the collar. For example, the frame portion has a flange shape. And it is preferable to make the frame part also nonmagnetic and nonconductive.
[0014]
At least one of the primary side coil and the secondary side coil, desirably both, is molded with a non-magnetic and non-conductive material to enhance impact resistance. Further, at least one of the primary side coil and the secondary side coil, and preferably both of them are edgewise coils, and are adapted for high power use. By making the mating surface of the primary side core and the secondary side core into a tapered surface, the magnetic path resistance can be lowered. If the tip of the rod-shaped guide part is rounded or has a curved taper shape, it can be easily inserted into the guide hole.
[0015]
By making the guide hole into a shape in which the tip portion of the column portion is fitted, the magnetic coupling state of the core can be improved. Furthermore, a tapered surface may be formed in the guide hole. When the guide portion is inserted into the guide hole, a certain gap or more is always maintained between the primary side coil and the secondary side coil.
[0016]
Providing an air passage leading to the outside inside the primary side core and / or the secondary side core can suppress an increase in loss due to a temperature rise of the core. The air passage includes an air passage that allows the cooling air sent from the primary side to circulate, or an air passage that sucks in from the outside of the secondary saddle core and circulates the cooling air.
[0017]
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 shows an embodiment of a non-contact power feeding coupler according to the present invention.
The non-contact power feeding coupler shown in FIG. 1 is of a magnetic coupling type, and includes a primary side magnetic unit 10 and a secondary side magnetic unit 20. Both units 10 and 20 correspond to a primary coil and a secondary coil of the transformer, and are magnetically coupled to each other to transmit alternating current (high frequency) power while maintaining an electrically non-contact state.
[0018]
The primary magnetic unit 10 includes a soft magnetic core 11 made of ferrite, a primary coil 12 that excites the core 11, a rod-shaped guide portion 15 made of nonmagnetic and nonconductive material, and a flange shape made of nonmagnetic and nonconductive material. The frame portion 16 is used. Each member (11, 12, 15, 16) is assembled integrally.
[0019]
The core 11 on the primary side is integrally formed with a disk-shaped flange portion 11a and a columnar portion 11b protruding vertically from the center of the flange portion 11a, and the cross section is formed in a substantially T-shape (weight shape). . A tapered surface 13 that recedes obliquely when viewed from the columnar part 11b side is formed on the outer peripheral edge of the flange part 11a. Moreover, the taper surface 14 in which the diameter of the cylinder continuously decreases toward the tip is formed at the tip of the cylinder portion 11b.
[0020]
The primary coil 12 is wound around the cylindrical portion 11 b of the T-shaped core 11 with a certain thickness. The coil 12 is an edgewise coil suitable for high power use, and is molded with a nonmagnetic and nonconductive material in order to prevent damage due to impact or the like. The rod-shaped guide portion 15 has a round bar shape slightly smaller in diameter than the column portion 11b, and is attached so as to protrude straight from the tip of the column portion 11b coaxially with the column portion. The rod-shaped guide portion 15 has a diameter smaller than that of the cylindrical portion 11b. However, since the tapered surface 14 is formed at the tip portion of the cylindrical portion 11b, there is no step between the cylindrical portion 11b. .
[0021]
The flange-shaped frame portion 16 has a disk shape larger in diameter than the flange portion 11a, and is attached to the upper surface of the flange portion 11a so as to protect the outline of the flange portion 11a. In addition to reinforcing and protecting the flange portion 11a, the frame portion 16 also serves as a lead wire lead-out portion of the coil 12.
[0022]
The rod-shaped guide portion 15 is made of a nonmagnetic and nonconductive material. This is to prevent the occurrence of magnetic loss and eddy current loss. Furthermore, a material having impact resistance and surface lubricity, for example, a polyamide or polyester high strength resin is desirable. The flange-like frame portion 16 is also made of a non-magnetic and non-conductive material for the same reason, and this is preferably made of a material having impact resistance and surface lubricity. Specifically, for example, polyamide or polyester-based high-strength resin can be used. Both the guide portion 15 and the frame portion 16 are firmly integrated with the core 11 by adhesion or the like.
[0023]
Corresponding to the primary side magnetic unit 10, the secondary side magnetic unit 20 has a soft magnetic core 21 made of ferrite and a secondary side coil 22 having the core 21 as a magnetic core.
The secondary side core 21 has a right cylindrical shape, and a secondary side coil 22 is wound along the inner surface of the collar. The coil 22 is an edgewise coil suitable for high power use, and is molded with a nonmagnetic and nonconductive material in order to prevent damage due to impact or the like. The opening of the saddle-shaped core 21 fits the flange 11a of the primary core 11 in terms of size and shape, and is tightly covered by the flange 11a (FIG. 2). For this reason, a tapered surface 23 is formed on the opening edge of the saddle-shaped core 21 so as to be in surface contact with the tapered surface 13 of the flange portion 11a. In addition, a guide hole 25 is provided at the center of the bottom surface of the saddle-shaped core 21 to guide the columnar portion 11b to the center position through the rod-shaped guide portion 15. A tapered surface 24 is formed in the guide hole 25. The tapered surface 24 serves as an insertion guide for the rod-shaped guide portion 15 and is in surface contact with the tapered surface 14 of the cylindrical portion 11b corresponding to the shape. That is, the tip end portion of the cylindrical portion 11a is fitted.
[0024]
FIG. 2 shows a power supply coupling state of the contactless power supply coupler described above.
In the coupled state shown in the figure, the primary-side core 11 and the secondary-side core 21 are positioned with respect to each other by the primary-side guide portion 15 and the secondary-side guide hole 25, and the cross section is EI type or EE type. A closed magnetic circuit is formed. When alternating current is supplied to the primary coil 12 in this state, an electromotive force is generated in the secondary coil 22 due to the excitation by the supply, and non-contact power transmission is performed from the primary side to the secondary side.
[0025]
Since both the primary and secondary cores 11 and 21 form a three-dimensional cylindrical closed magnetic path, a large magnetic path area can be obtained for the volume. Thereby, the non-contact power feeding coupler can handle a large transmission power for its outer diameter R. In order to fit into the refueling port of a general gasoline vehicle, it is desirable to have an outer diameter of 10 cm or less. However, even with such a relatively small outer diameter (R ≦ 10 cm), the electric power can be used to quickly charge an electric vehicle. Can be rated.
[0026]
In the embodiment, the T-shaped core 11 and the saddle-shaped core 21 are arranged so that the tapered surfaces 13 and 23 meet each other. The surface contact between the tapered surfaces is the contact area between the cores 11 and 21. It is suitable for securing a large value to lower the magnetic path resistance. The decrease in magnetic path resistance has the same effect as increasing the magnetic path area equivalently. Furthermore, in the embodiment, the secondary side coil 22 is arranged on the inner side surface of the saddle-shaped core 21, but this makes it possible to make the entire coupler magnetically shielded with a cylindrical magnetic body. This is effective in preventing electromagnetic noise radiation and avoiding a decrease in efficiency due to magnetic flux leakage.
[0027]
The above-described feed coupling state can be formed easily and accurately by mounting the primary side magnetic unit 10 on the secondary side magnetic unit 20 while leaving the primary side magnetic unit 10 to be guided by the guide portion 15 and the guide hole 25. When the power supply is finished and the coupling is released, the primary side magnetic unit 10 may be pulled up and removed. This operation of attachment / detachment can be performed easily and neatly even by an unskilled person with the same operation feeling as inserting a fuel filler nozzle into the fuel filler port of a gasoline vehicle. Moreover, even if the vehicle is started accidentally during power feeding, the primary side magnetic unit 10 is simply detached, and this does not immediately damage the coupler or the charging device.
[0028]
Further, the secondary side saddle-shaped core 21 is formed in a cylindrical shape, and the primary side T-shaped core 11 is also formed so as to have a columnar part 11b and a disk-like saddle part 11a. Thereby, the primary side magnetic unit 10 and the secondary side magnetic unit 20 can be mutually coupled from any direction. That is, in the operation of mounting the primary side magnetic unit 10 to the secondary side magnetic unit 20, alignment in the rotational direction is not necessary. Thereby, operativity can further be improved.
[0029]
The length h1 of the rod-shaped guide portion 15 is larger than the depth h2 of the secondary saddle-shaped core 21 (FIG. 1). Thus, the primary coil 12 can be separated from both the secondary core 21 and the coil 22 until the guide portion 15 is inserted into the guide hole 25 and guided. it can. The primary side coil 12 enters the secondary side core 21 when the guides 15 and the guide holes 25 are in a state of being surely operated. Thereby, when attaching the primary side magnetic unit 10 to the secondary side magnetic unit 20, it is possible to reliably prevent the primary side coil 12 from hitting the secondary side core 21 or the secondary side coil 22.
[0030]
FIG. 3 shows a state when the primary side magnetic unit 10 is mounted on the secondary side magnetic unit 20 and an enlarged cross section near the guide hole 25 for guiding the mounting thereof.
As described above, the primary-side magnetic unit 10 can be accurately mounted on the secondary-side magnetic unit 20 while leaving it to guide by the guide portion 15 and the guide hole 25. As described above, it is desirable to always maintain a certain gap (> d) between the primary coil 12 and the secondary coil 22. That is, when the primary side magnetic unit 10 is mounted on the secondary side magnetic unit 20, the end of the primary side coil 12 is prevented from hitting the end of the secondary side coil 22.
[0031]
For this purpose, as shown in the figure, the length and shape of the guide hole 25 may be determined so that the tiltable range of the guide portion 15 inserted into the guide hole 25 can be regulated. A taper surface 24 is formed in the guide hole 25, and the taper surface 24 guides the guide portion 15 easily. However, if the inclination of the taper surface 24 is increased to some extent, the gap (> It is possible to set a tiltable range in which d) can be secured. When the inclination of the taper surface 24 is increased, the insertion guide range of the guide portion 15 by the taper surface 24 is narrowed. This is because the tip of the guide portion 15 is rounded or the tip is formed into a curved taper. It can be solved by doing.
[0032]
FIG. 4 shows a state in which the primary magnetic unit 10 is dropped on the ground or a concrete surface. The primary side magnetic unit 10 may be dropped by the user by mistake. In this case, when the core 11 made of ferrite hits a hard surface such as concrete, there is a high probability that the core 11 is cracked by an impact. However, as shown in the figure, when the primary side magnetic unit 10 described above is placed on the ground or the like, it is the rod-shaped guide portion 15 and the flange-shaped frame portion 16 that touch the ground and the like. 11 is floating away from the ground. Therefore, even if the primary magnetic unit 10 is accidentally dropped, the core 11 is protected and can be prevented from being damaged.
[0033]
As described above, the above-described contactless power feeding coupler is suitable for relatively large power feeding, and can be made compact so that it can be accommodated in a fueling port of an existing gasoline vehicle, for example. Even a person can easily and smartly operate, and even if misused, there is an advantage that it is not easily damaged.
[0034]
FIG. 5 shows a further preferred embodiment of the present invention.
In the non-contact power feeding couplers shown in FIGS. 3A to 3C, the air passage 17 leading to the outside is provided inside the primary side core 11 and / or the secondary side core 21, so that the core 11 can be used during power feeding. , 12 can be cooled. The arrows in the figure indicate the air flow paths formed by the ventilation paths 17.
[0035]
As shown in (a) or (c), for cooling, if air is sent from the flange-side frame 16 side on the primary side, forced air cooling of the cores 11 and 21 is performed only by the equipment on the power supply side. Can do. When it is difficult to provide an air supply facility on the power supply side, intake may be performed from the outside of the saddle core 21 on the power reception side, as shown in (b). In either case, the cores 11 and 21 can be efficiently air-cooled.
[0036]
The cores 11 and 21, which are magnetic materials, have characteristics that decrease due to temperature rise and increase loss. However, the cooling can suppress an increase in loss due to the characteristics deterioration. Thereby, the power rating of the non-contact power feeding coupler can be increased.
[0037]
Further, even if forced air supply or intake is not performed, a cooling effect by natural convection can be obtained to some extent only by providing the air passage 17 leading to the outside as shown in (a) to (c).
[0038]
FIG. 6 shows another embodiment of the present invention. In the non-contact power feeding coupler of this embodiment, the flange portion 11a of the primary side core 11 and the opening edge portion of the secondary side core 21 are formed flat rather than tapered, but the cores 11 and 21 having such a shape are formed. Even so, the main effects of the present invention can be sufficiently obtained.
[0039]
As mentioned above, although this invention was demonstrated based on the typical Example, this invention can have various aspects other than having mentioned above. For example, the primary-side flange-like frame portion 16 may be a cylindrical or other shape frame portion. Further, the present invention is not limited to an electric vehicle, and can be applied to non-contact power feeding such as an electric bicycle or a power tool.
[0040]
【The invention's effect】
According to the present invention, it is suitable for power supply of relatively large power, and can be made compact so that it can be accommodated in, for example, an oil filling port of an existing gasoline vehicle. It is possible to provide a non-contact power feeding coupler that can be operated and is not easily damaged even if it is misused. In addition, by making the length of the rod-shaped guide part larger than the depth of the secondary saddle-shaped core, the coil on the primary side is fixed until the guide part is inserted into the guide hole and guided. It can be separated from both the secondary core and coil, and the primary coil enters the secondary core when the guide and guide holes are in a reliable state. Therefore, when the primary side magnetic unit is attached to the secondary side magnetic unit, it is possible to reliably avoid the primary side coil from hitting the secondary side core or the secondary side coil.
[Brief description of the drawings]
FIG. 1 is a cross-sectional view and a perspective view showing an embodiment of a non-contact power feeding coupler according to the present invention.
FIG. 2 is a cross-sectional view showing a power supply coupling state of a non-contact power supply coupler according to the present invention.
FIG. 3 is an enlarged cross-sectional view of a state when a primary side magnetic unit is mounted on a secondary side magnetic unit and a part thereof.
FIG. 4 is a cross-sectional view showing a state in which the non-contact power feeding coupler according to the present invention is dropped on the ground or the like.
FIG. 5 is a cross-sectional view showing a further preferred embodiment of the non-contact power feeding coupler according to the present invention.
FIG. 6 is a cross-sectional view showing another embodiment of the present invention.
[Explanation of symbols]
10 Primary side magnetic unit 11 Primary side core (soft magnetic core)
11a ridge portion 11b cylindrical portion 12 primary side coil 13 taper surface 14 taper surface 15 rod-shaped guide portion 16 flange-shaped frame portion 17 air passage 20 secondary side magnetic unit 21 secondary side core (soft magnetic core)
22 Secondary coil 23 Tapered surface 24 Tapered surface 25 Guide hole h1 Length h2 of rod-shaped guide portion 15 Depth of saddle-shaped core 21 on the secondary side

Claims (19)

The primary side magnetic unit and the secondary side magnetic unit each having a soft magnetic core and a coil are magnetically coupled so as to be detachable so that power can be transmitted from the primary side to the secondary side in an electrically non-contact manner. The non-contact power feeding coupler includes the following constituent means (1) to ( 5 ).
(1) The primary side core has a collar part and a column part, and the cross section is formed in a substantially T shape.
(2) A rod-shaped guide portion having a diameter smaller than that of the column portion is attached to the tip of the column portion so as to protrude coaxially.
(3) The secondary-side core is formed in a saddle shape and forms a closed magnetic circuit together with the primary-side core.
(4) The length of the said rod-shaped guide part is larger than the depth of the core of the secondary side formed in the said saddle shape.
(5) A guide hole for guiding the insertion of the rod-shaped guide portion is provided at the center of the bottom surface of the secondary-side core formed in the saddle shape.   2. The non-contact power feeding coupler according to claim 1, wherein the flange portion has a disk shape.   3. The non-contact power feeding coupler according to claim 1, wherein the pillar portion is a columnar shape.   The contactless power supply coupler according to claim 1, wherein a primary side coil is wound around the column portion.   5. The non-contact power feeding coupler according to claim 1, wherein the saddle type core is cylindrical.   6. The non-contact power feeding coupler according to claim 1, wherein a secondary coil is wound along an inner surface of the saddle type core.   7. The non-contact power feeding coupler according to claim 1, wherein the rod-shaped guide portion is nonmagnetic and nonconductive.   The non-contact power feeding coupler according to claim 1, wherein a frame portion having a diameter larger than that of the flange portion is attached to the upper surface of the flange portion.   9. The non-contact power feeding coupler according to claim 8, wherein the frame portion has a flange shape.   10. The non-contact power feeding coupler according to claim 8, wherein the frame portion is nonmagnetic and nonconductive.   11. The non-contact power feeding coupler according to claim 1, wherein at least one of the primary side coil and the secondary side coil is molded with a nonmagnetic and nonconductive material.   The contactless power feeding coupler according to claim 1, wherein at least one of the primary side coil and the secondary side coil is an edgewise coil.   The contactless power supply coupler according to claim 1, wherein a mating surface of the primary side core and the secondary side core is a tapered surface.   The contactless power supply coupler according to claim 1, wherein a tip of the rod-shaped guide portion is rounded or has a curved taper shape.   The non-contact power feeding coupler according to claim 1, wherein the guide hole has a shape in which a tip portion of the pillar portion is fitted.   16. The non-contact power feeding coupler according to claim 1, wherein a tapered surface is formed in the guide hole.   17. The non-contact power feeding coupler according to claim 1, wherein an air passage leading to the outside is provided inside the primary side core and / or the secondary side core.   18. The non-contact power feeding coupler according to claim 17, wherein a ventilation path is formed so as to circulate the cooling air sent from the primary side.   19. The non-contact power feeding coupler according to claim 18, wherein a ventilation path is formed to suck air from outside the saddle core on the secondary side and distribute cooling air.

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