JP6580387B2 - Coil unit - Google Patents

Description

  The present invention relates to a coil unit.

  2. Description of the Related Art Conventionally, as a system for charging a battery mounted on a vehicle such as an electric vehicle, a secondary coil is changed from a primary coil by an interaction between a primary coil installed on a road surface side and a secondary coil installed on a vehicle side. There is known a non-contact power feeding system that charges a battery with electric power supplied to the battery (see, for example, Patent Document 1).

  In this type of system, a primary coil and a secondary coil (hereinafter referred to as a coil) are housed in a case and unitized. Hereinafter, an example of a conventional coil unit will be described.

  7 is a top view showing the internal structure of the coil unit in which the coil is housed in the case, FIG. 8 is a cross-sectional view taken along the line CC in FIG. 7, and FIG. 9 is a cross-sectional view taken along the line DD in FIG. . As shown in FIGS. 7 and 8, the case 11 is formed by erecting a frame-shaped side wall 15 having a rectangular cross section from the periphery of the bottom wall 13, and a lid (not shown) is put on the upper part of the case 11.

  A resin coil guide 17 is accommodated inside the case 11. As shown in FIG. 8, the coil guide 17 has a substrate 19 formed in a rectangular band shape, an inner guide wall 21 that rises in a frame shape from the inner peripheral edge of the substrate 19, and a frame shape that rises in a frame shape from the outer peripheral edge of the substrate 19. The outer guide wall 23 is formed. A flat coil 27 around which the electric wire 25 is wound is accommodated in the coil guide 17, and a buffer sheet 29 for adjusting the height of the coil 27 is provided between the coil 27 and the bottom wall 13. A magnetic material such as ferrite (not shown) is accommodated in the space S surrounded by the coil guide 17.

  As shown in FIG. 7, the coil 27 is wound around a plurality of locations in the winding direction of the electric wire 25, so that the electric wires 25 are arranged in the width direction of the coil guide 17 (the horizontal direction in the drawing). For example, two layers are held in the thickness direction (vertical direction in the figure).

Japanese Patent Application Laid-Open No. 2015-12764

  However, this type of coil 27 not only takes time and labor for winding the tape 31, but also when the tape 31 is wound as shown in FIG. 9, the electric wire 25 is likely to be displaced in the width direction and the thickness direction. The cross-sectional dimensions (width dimension L1 and thickness dimension L2) of the coil 27 may vary. Further, when the coil guide 17 heated with the heat generation of the coil 27 is deformed due to thermal expansion or contraction, the cross section of the coil 27 pressed against the deformed coil guide 17 may be deformed, and the cross sectional dimension may be changed. is there.

  In such a case, for example, when the width L1 of the coil 27 is smaller than the design value, the transmission efficiency and the charging efficiency of the coil 25 are lowered. Moreover, when the thickness dimension L2 becomes larger than the design value, the coil 27 protrudes from the coil guide 17 and the assemblability deteriorates.

  This invention is made | formed in view of such a problem, and makes it a subject to aim at stabilization of the cross-sectional dimension of a coil.

  In order to solve the above problems, a coil unit according to the present invention includes a case in which a side wall is erected from the periphery of a bottom wall and an upper surface is opened, and a coil formed by winding an electric wire in a flat shape along the bottom wall. A coil guide for positioning in the case, and the coil guide is formed by arranging a plurality of wire receiving grooves separated from each other in parallel.

  According to this, the coil can be easily formed by assembling the electric wire in the electric wire receiving groove. Further, since the position of the electric wire can be regulated by the electric wire receiving groove, the coil can be held in the case by holding the coil guide in which the electric wire is assembled at a predetermined position in the case. In particular, since the electric wire assembled in the electric wire receiving groove is separated from each other, adjacent electric wires do not contact each other. Thereby, since the position shift of the electric wire can be surely prevented, the necessary coil dimensions can be secured with a small number of electric wires, and the coil cross-sectional dimensions can be stabilized.

  In this case, the coil guide is preferably divided in the winding direction of the electric wire. If the coil guide is divided in this way, the volume of each coil guide can be reduced, and deformation due to thermal expansion and contraction of the coil guide can be suppressed when the coil generates heat. Can be achieved.

  Further, the case is formed by opening the upper surface of the side wall in a rectangular shape, and the coil guide is divided into L-shapes and arranged along the four corners of the side wall. It is preferable to be held by

  According to this, the coil guide heated by the heat generated by the coil has the corners and corners held by the case, so that the deformation of the L-shaped bent part is suppressed, and the dimensions of the linear parts on both sides thereof change. To do. However, the dimensional change of the linear part is mainly due to linear expansion and contraction along the side wall, and does not affect the arrangement of the wires, so that the cross-sectional dimension of the coil can be maintained.

  Moreover, it is preferable that the coil guide is formed with slits or holes extending on straight lines connecting the corner portions and the corner portions, and the projections on the case side are respectively engaged with the slits or holes. According to this, since the protrusion can be relatively moved along the slit or the hole when the coil guide is thermally expanded or contracted by forming the protrusion small with respect to the slit or the hole, the distortion of the coil guide is reduced. Can be reduced, and damage and deformation can be suppressed.

  Moreover, it is preferable that the electric wire accommodation groove | channel is each set to the groove depth which hold | maintains several electric wires in a layer form. According to this, by assembling a plurality of electric wires in each electric wire receiving groove, even if the electric wires are arranged in a layered manner, there is no displacement in each layer, so that the cross-sectional dimension of the coil can be stabilized. Can do.

  According to the present invention, it is possible to stabilize the sectional dimension of the coil.

It is a top view which shows the internal structure of the coil unit to which this invention is applied. It is AA arrow sectional drawing of FIG. It is a top view of the state which removed the coil from FIG. It is a top view of a coil guide. It is a BB arrow sectional view of Drawing 4. It is a top view of other embodiments of a coil guide. It is a top view which shows the internal structure of the conventional coil unit. It is CC sectional view taken on the line of FIG. It is DD sectional view taken on the line of FIG.

  Hereinafter, an embodiment of a coil unit to which the present invention is applied will be described with reference to FIGS. 1 to 5. The present embodiment relates to a power receiving coil unit that is mounted on the vehicle side and accommodates a secondary coil in a non-contact power feeding system for charging a battery mounted on a vehicle such as an electric vehicle or a hybrid car. is there. However, the coil unit of the present invention is not limited to this example. For example, in the non-contact power feeding system, in addition to the power feeding coil unit that houses the primary coil and is installed on the road surface side, various coils can be used. The present invention can also be applied to a coil unit in which is stored.

  In the non-contact power supply system using the coil unit of the present embodiment, electric power is supplied to the secondary coil on the vehicle side by utilizing the interaction with the primary coil on the road surface side, that is, electromagnetic induction. The supplied power is charged in the battery.

  As shown in FIG. 1, the coil unit 33 of the present embodiment includes a case 35, a coil 37 accommodated in the case 35, and a coil guide 39 that positions the coil 37 in the case 35. .

  The case 35 is formed of resin or the like, and includes a flat bottom wall 41 and a frame-like side wall 43 that stands up from the periphery of the bottom wall 41 and has a rectangular cross section as shown in FIG. The upper surface is formed with a rectangular opening 45. The opening 45 is sealed by covering a cover (not shown) via a packing and fixing with a screw.

  As shown in FIG. 1, the coil 37 is formed in a flat shape by winding an electric wire 47 along the bottom wall 41 of the case 35, and is positioned on the coil guide 39. The coil 37 has a rectangular band shape as a whole when viewed from the opening 45 side of the case 35. Although not shown, an electrical component such as a phyllite or a capacitor that is a magnetic material is disposed inside the coil 37. One end side of the electric wire 47 is connected to an inner electrical component, and after being wound from the inner peripheral side toward the outer peripheral side, the other end side is drawn inward to be connected to another electric component.

  The coil guide 39 is formed of resin or the like and includes four L-shaped coil guides 39a to 39d as shown in FIG. That is, each of the coil guides 39a to 39d is formed by dividing a plate material formed in a rectangular frame shape in the winding direction of the electric wire 47 so as to have the same outer shape centering around the corner.

  As shown in FIG. 4, each of the coil guides 39 a to 39 d extends from the outer peripheral surface of the bent portion in the horizontal direction and protrudes in the horizontal direction from the inner peripheral surface. The first piece 49 has a first through hole 53 formed in the first piece 49, and the second piece 51 has a second through hole 55. Is formed. When viewed from the upper surface side, the first piece portion 49 is formed by extending the extended lines along the outer side surfaces of the straight portions 56 and 56 on both sides of the bent portion in an R shape, and corresponds to the four corners of the case 35. It has a shape.

  As shown in FIGS. 1 and 2, the coil guides 39 a to 39 d are arranged along the four corners of the side wall 43 of the case 35 and are inscribed in the side wall 43. The bolts respectively inserted into the through holes 55 are fastened to the bolt holes in the bottom wall 41, so that the corners and corners are positioned in the case 35. The coil guides 39a to 39d are positioned by inserting bosses standing from the bottom wall 41 of the case 35 into the first through hole 53 and the second through hole 55, respectively, instead of bolt fastening. It may be.

  As shown in FIG. 3, the coil guides 39a to 39d are positioned at the four corners of the case 35, and the end faces 57 are arranged apart from each other.

  As shown in FIG. 4, a plurality of electric wire receiving grooves 59 that extend in the winding direction of the electric wire 47 and are assembled with the electric wire 47 are formed on the upper surfaces of the coil guides 39 a to 39 d. Each of the coil guides 39a to 39d is provided with the same number of wire receiving grooves 59 as the number of windings of the electric wires 47, and each of the wire receiving grooves 59 has an adjacent wire receiving groove 59 and a partition wall 61 as shown in FIG. Are isolated from each other. Each wire receiving groove 59 has a groove bottom having a R-shaped cross section, and holds a groove width L3 that is the same as or slightly larger than the outer diameter of the wire 47 and a plurality of (two in FIG. 5) wires 47. And a groove depth L4 to be formed. In the present embodiment, two electric wires 47 are accommodated in each electric wire accommodating groove 59, and at least half of the electric wires 47 positioned above are accommodated in the electric wire accommodating grooves 59.

  As described above, in the present embodiment, the flat coil 37 can be easily formed manually by assembling the electric wires 47 along the electric wire receiving grooves 59 respectively formed in the coil guides 39a to 39d. it can. Further, the coil 37 can be held in the case 35 by positioning the coil guides 39a to 39d in which the electric wires 47 are assembled in the case 35 as described above.

  Moreover, since each electric wire accommodation groove | channel 59 is isolated from the adjacent electric wire accommodation groove | channel 59, the contact between adjacent electric wires 47 can be prevented, and also the operation | work which winds with the tape 31 like FIG. 7 is unnecessary. Therefore, the positional deviation between the electric wires 47 can be reliably prevented. Thereby, since the cross-sectional shape of the coil 37 is made uniform, the necessary cross-sectional dimensions of the coil 37 (L5 and L6 in FIG. 5) can be secured with a small number of wires 47, and the charging efficiency of the coil 27 can be increased. Can be stabilized. In addition, since the coil guides 39a to 39d of the present embodiment share the coil guide 17 and the buffer sheet 29 of FIG. 8, the number of parts can be reduced.

  Moreover, since the coil guide 39 of this embodiment is comprised by the four coil guides 39a-39d, a volume can be made small rather than comprising only one like the coil guide 17 of FIG. Thereby, since the dimensional change by thermal expansion and contraction of coil guide 39a-39d can be suppressed at the time of the heat_generation | fever of the coil 37, the change of the cross-sectional dimension of the coil 37 accompanying this dimensional change can be suppressed. Note that the coil guide 39 may be formed of a single sheet as long as it is formed of a material that hardly causes thermal expansion or contraction.

  Further, the coil guides 39a to 39d of the present embodiment are arranged along the four corners of the side wall 43 of the case 35 formed in a rectangular shape, and the corners and corners of the L-shape are respectively positioned on the case 35. Yes. Therefore, when the coil guides 39a to 39d undergo thermal expansion or contraction due to the heat generated by the coil 37, deformation of the positioned L-shaped bent portions is suppressed. On the other hand, since the straight portions 56 on both sides of the bent portion are separated from the adjacent coil guide 39 and are not restrained, they extend and contract in the direction extending along the side wall 43 of the case 35 (the arrow in FIG. 3 indicates the contraction direction). Yes) Therefore, even if the linear portion 56 is deformed in this way, the arrangement of the electric wires 47 is not affected, and thus the variation in the cross-sectional dimension of the coil 37 can be prevented.

  The embodiment of the present invention has been described in detail with reference to the drawings. However, the present embodiment is merely an example of the present invention, and can be changed or modified within the scope of the claims.

  For example, in the present embodiment, an example in which the coil guides 39a to 39d are respectively formed in an L shape has been described. Thus, the coil guides 39a to 39d can be formed in an arc shape.

  Moreover, the coil guides 39a to 39d of the present embodiment form positioning through holes in the first piece 49 and the second piece 51, respectively, and fasten bolts inserted into these through holes to the case. Thus, the case 35 is positioned, but the positioning structure for the case 35 is not limited to such bolt fastening, and can be configured as follows.

  As shown in FIG. 6, a slit 63 is formed in the first piece 49 instead of the first through hole 53, and a second through hole 55 is substituted in the second piece 51. A long hole 65 extending in the longitudinal direction of the slit 63 is formed. In this case, the slit 63 and the long hole 65 are formed extending along a straight line P connecting them. A rib 67 extending from the side wall 43 of the case 35 is engaged with the slit 63 along the straight line P, and a boss 69 erected from the bottom wall 41 of the case 35 is engaged with the elongated hole 65. The The rib 67 and the slit 63 are provided with a gap in the direction along the straight line P, and the elongated hole 65 and the boss 69 are provided with a gap in the direction along the straight line P.

  According to this, when thermal expansion or contraction occurs in the coil guides 39a to 39d, the rib 67 and the slit 63, and the long hole 65 and the boss 69 can be moved relative to each other in the straight line P direction. The bent portions of the coil guides 39a to 39d are allowed to have predetermined thermal expansion and contraction in the direction of the straight line P. As a result, when the first piece 49 and the second piece 51 are fastened with bolts, respectively. The generated distortion is reduced. Therefore, breakage and deformation of the coil guides 39a to 39d can be prevented and durability can be improved.

33 Coil unit 35 Case 37 Coil 39a to 39d Coil guide 41 Bottom wall 43 Side wall 45 Opening 47 Electric wire 49 First piece (corner)
51 Second piece (corner)
59 Wire receiving groove 61 Bulkhead 63 Slit 65 Slotted hole

Claims (3)

A case in which the side wall is erected from the peripheral edge of the bottom wall and the upper surface is opened in a rectangular shape; and a coil guide that positions a coil formed by winding a wire in a flat shape along the bottom wall in the case. ,
The coil guide has a plurality of wire receiving grooves that are separated from each other and are divided into L shapes in the winding direction of the wires and arranged along the four corners of the side wall. Coil units each having a corner held by the case . The coil guide, the said angle portion and the corner portion is a slit or a hole extending on the straight line connecting these is formed respectively, in claim 1, the slit or of each of the holes the case-side projection is engaged The coil unit described. The coil unit according to claim 1 or 2 , wherein each of the electric wire receiving grooves is set to a groove depth for holding the plurality of electric wires in layers.

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