JP6642330B2 - Coil unit - Google Patents

Description

  The present disclosure relates to a coil unit, and more particularly, to a coil unit used in a non-contact charging system.

  Conventionally, various proposals have been made for a power receiving device and a power transmitting device used in a non-contact charging system.

  For example, the power receiving device described in JP-A-2006-129191 includes a case, a metal plate, a power receiving coil, a ferrite, and a capacitor housed in the case.

  The case includes a metal top plate and a resin lid provided to cover the top plate from below.

  The metal plate is arranged in a case, and a ferrite and a power receiving coil are arranged on a lower surface of the metal plate.

  The metal plate includes a flat portion and a protruding portion protruding downward from the center of the flat portion, and the ferrite and the power receiving coil are arranged on the lower surface of the flat portion. The coil is formed so as to surround the periphery of the protrusion. An electric device such as a capacitor is arranged in the protruding portion and between the top plate and the metal plate.

JP-A-2006-129191 JP 2013-146154 A JP 2013-146148 A JP 2013-110822 A JP 2013-126327 A JP 2013-154815 A

  In the power receiving device described in JP-A-2006-129191, when a central portion of the power receiving device interferes with the ground or the like, a protruding portion of a metal plate may be deformed and electric equipment may be damaged.

  In view of the above problems, the present inventors have studied the following new power receiving devices. The power receiving device studied by the inventors includes a metal support column formed on a top plate, and the support column is formed to support a central portion of the metal plate.

  The inventors have found that in the above-described power receiving device, it is necessary to ensure a creepage distance between the metal support pillar and the electric device, and as a result, the space in which the electric device can be arranged is substantially reduced. Was found to decrease significantly.

  Note that the above-described problem occurs not only in the power receiving device but also in the power transmitting device.

  The present disclosure has been made in view of the above-described problems, and an object of the present disclosure is to provide a coil unit such as a power receiving device and a power transmission device that can protect an electric device or the like from external force from outside. Another object of the present invention is to provide a coil unit capable of securing a housing space in which electric devices and the like can be housed.

  A coil unit according to an embodiment of the present disclosure includes a metal case main body disposed on an external fixing member, a resin cover provided to cover the case main body, and a case in which a housing space is formed, A support plate including an electric element housed in the case, a first main surface facing the case body, and a second main surface opposite to the first main surface, housed in the case; The ferrite includes a ferrite disposed on the second main surface of the plate, and a spiral coil disposed on the ferrite and having a hollow portion. The case main body includes a metal supporting portion that supports a portion of the first main surface that faces the coil. The lid includes a main plate and a resin support portion made of resin formed to extend from the main plate toward the case body. One end of the resin support is supported by the case body.

  According to the above-described coil unit, the metal supporting portion supports the portion of the support plate on which the coil and the ferrite are provided, and the portion is suppressed from being significantly deformed. For this reason, it is possible to suppress deformation of the coil and cracking of the ferrite. Further, since the metal support portion and the resin support portion support the external force, the coil unit can be prevented from being greatly deformed, and the ferrite and the coil in the coil unit and the electric device are prevented from being damaged. . Further, since the resin support portion is formed of resin, it is not necessary to secure a creepage distance between the electric device and the resin support portion, and the electric device can be arranged near the resin support portion. A large space for accommodating equipment can be secured.

  ADVANTAGE OF THE INVENTION According to the coil unit of this indication, while accommodating an electric device etc. from external force from the outside, the accommodation space which can accommodate an electric device etc. can be ensured.

It is a schematic diagram which shows the non-contact charging system 1 typically. 1 is an electric circuit diagram schematically showing a non-contact charging system 1. FIG. 3 is an exploded perspective view showing the coil unit 4. It is sectional drawing which shows the coil unit 4 typically.

  The coil unit according to the embodiment will be described with reference to FIGS. In addition, among the configurations shown in FIGS. 1 to 4, the same configuration or substantially the same configuration is denoted by the same reference numeral, and a repeated description may be omitted.

  FIG. 1 is a schematic diagram schematically illustrating the non-contact charging system 1, and FIG. 2 is an electric circuit diagram schematically illustrating the non-contact charging system 1. In FIG. 1 and the like, “U” indicates an upward direction. “D” indicates a downward direction. As shown in FIGS. 1 and 2, the contactless charging system 1 includes a vehicle 2 on which a coil unit 4 and a battery 7 are mounted, and a coil unit 3 provided outside the vehicle 2.

  The coil unit 4 is provided on the lower surface of the floor panel 15 of the vehicle 2 and receives power from the coil unit 3 in a non-contact manner. The coil unit 4 may be mounted not only on the floor panel 15 but also on the lower surface of a battery provided on the lower surface of the floor panel 15, for example.

  The coil unit 4 includes a resonator 5 and a rectifier 6 connected to the resonator 5. The resonator 5 includes a power receiving coil 8 and a capacitor 9, and the power receiving coil 8 and the capacitor 9 form an LC resonance circuit. The rectifier 6 converts AC power received by the resonator 5 into DC power and supplies the DC power to the battery 7.

  The coil unit 3 is fixed to the ground or a fixed plate arranged on the ground. Coil unit 3 includes a resonator 14 and a converter 11. The resonator 14 includes the power transmission coil 12 and the capacitor 13, and the power transmission coil 12 and the capacitor 13 form an LC resonance circuit.

  The converter 11 is connected to the power supply 10, adjusts the frequency of the alternating current supplied from the power supply 10, adjusts the voltage, and supplies the adjusted voltage to the resonator 14.

  FIG. 3 is an exploded perspective view showing the coil unit 4. As shown in FIG. 3, the coil unit 4 includes a housing case 20, a power receiving coil 8, a bobbin 23, a ferrite plate 24, a support plate 25, and a substrate 26 housed in the housing case 20.

  The housing case 20 includes a case body 21 fixed to the floor panel 15 or a battery case provided on the lower surface of the floor panel 15 and a resin lid 22 provided to cover the case body 21 from below. The case main body 21 is formed of, for example, aluminum or an aluminum alloy.

  The case body 21 includes a top plate 30, an annular wall 31 formed on a lower surface 33 of the top plate 30, and a plurality of support walls 32 disposed in the annular wall 31. A pedestal 34 and an overhang 27 protruding outward are formed on the outer peripheral edge of the top plate 30. A screw hole 35 is formed in the pedestal 34, and a screw hole 28 is also formed in the overhang portion 27. Then, the bolt 42 is inserted into the screw hole 35, and the bolt 42 fixes the case body 21 (the housing case 20) to a floor panel of the vehicle 2 or a battery case arranged on the lower surface of the floor panel. The bolt 42 is formed of iron or the like.

  The annular wall 31 extends along the peripheral edge of the top plate 30. A plurality of bosses 38 are arranged between the annular wall portion 31 and the outer peripheral edge of the top plate portion 30, and a hole portion 39 is formed in the boss 38.

  The substrate 26 is fixed to the lower surface 33 of the case body 21, and the electric device 17 such as the capacitor 9 and the rectifier 6 is mounted on the lower surface 50 of the substrate 26. A plurality of slits 29 into which the support wall 32 is inserted are formed in the substrate 26.

  The support plate 25 is arranged on the lower surface 50 side of the substrate 26. The support plate 25 is formed of, for example, aluminum or an aluminum alloy.

  The support plate 25 is formed in a plate shape and includes an upper surface 18 facing the case main body 21 and a lower surface 19 located on the opposite side of the upper surface 18.

  The support plate 25 includes a flat portion 36 formed in a flat surface shape, and a protruding portion 37 formed to protrude downward from a central portion of the flat portion 36. A hole 40 is formed in the center of the protrusion 37.

  The ferrite plate 24 is arranged on the lower surface 19 side of the support plate 25. The ferrite plate 24 is formed in a plate shape. The ferrite plate 24 includes an upper surface 44 and a lower surface 45 arranged in the thickness direction TD.

  The ferrite plate 24 includes a plurality of divided ferrite plates 24 </ b> A arranged in an annular shape, and a hollow portion 51 is disposed at the center of the ferrite plate 24. The split ferrite plate 24A is disposed on the flat portion 36 of the support plate 25, and the protrusion 37 of the support plate 25 is disposed in the hollow portion 51.

  The bobbin 23 is arranged on the lower surface 45 side of the ferrite plate 24. The bobbin 23 is formed of resin or the like, and the bobbin 23 is formed in a plate shape and includes a lower surface 52 and an upper surface 53 arranged in the thickness direction. A hollow portion 54 penetrating from the lower surface 52 to the upper surface 53 is formed at the center of the bobbin 23, and a coil groove 43 is formed on the lower surface 52 of the bobbin 23 so as to surround the periphery of the hollow portion 54.

  A plurality of pins 16 are formed on the outer peripheral edge of the bobbin 23, and each pin 16 protrudes upward. The bobbin 23 is fixed to the case body 21 by inserting the pin 16 into the hole 39 of the boss 38.

  The power receiving coil 8 is housed in the coil groove 43. The power receiving coil 8 is formed so as to surround the winding axis O1 extending in the thickness direction TD. In the example shown in FIG. 3, the winding axis O1 extends vertically. The power receiving coil 8 is a spiral coil, and has a hollow portion 49 formed at the center.

  The resin lid 22 is disposed below the power receiving coil 8. The resin lid 22 includes a main plate 55, a peripheral wall portion 56 rising upward from an outer peripheral edge of the main plate 55, a flange portion 57 extending outward from an upper end side of the peripheral wall portion 56, and a plurality of flange portions 57 formed on the flange portion 57. An overhang portion 46 and a resin support shaft 58 protruding upward from the center of the upper surface of the main plate 55 are included.

  The overhang portions 46 are formed at intervals on the outer peripheral edge of the flange portion 57, and each overhang portion 46 has a hole 47. The resin lid 22 is fixed to the case body 21 by bolts 48. The bolt 48 is inserted into the hole 47 of the resin lid 22 and the screw hole 28 of the case main body 21 to fix the resin lid 22 to the case main body 21. The bolt 48 is formed of iron or the like.

  FIG. 4 is a cross-sectional view schematically showing the coil unit 4. As shown in FIG. 4, the case body 21 includes a pedestal 60 formed at the center of the lower surface 33 of the top plate 30, and a pedestal 61 formed on the outer peripheral edge side of the case body 21 with respect to the pedestal 60. , A support wall 32.

  The support wall 32 supports the upper surface 18 of the support plate 25, and the support wall 32 includes a support portion 63 and a support portion 64.

  The support portion 63 supports a portion of the upper surface 18 adjacent to the hollow portion 54 of the bobbin 23 in the thickness direction. The support portion 64 is formed on a portion of the upper surface 18 of the support plate 25 that faces the power receiving coil 8 (a portion that overlaps the power receiving coil 8 in the vertical direction).

  The pedestal 61 is formed at the base of the support part 63 and the top plate part 30, and the pedestal 61 supports the upper surface 70 of the substrate 26. The pedestal 60 is disposed substantially at the center of the top plate 30 or in the vicinity thereof.

  A slit 29 is formed in the substrate 26, and a support 63 is inserted into the slit 29, and the lower end of the support 63 reaches the upper surface 18 of the support plate 25. A hole 71 penetrating from the lower surface 50 to the upper surface 70 is formed in the center of the substrate 26. A plurality of electric devices 17 are arranged on the lower surface 50 of the board 26.

  The support plate 25 includes a flat portion 36 and a protruding portion 37 protruding downward from a central portion of the flat portion 36, and a hole 40 is formed in the central portion of the protruding portion 37.

  The distance between the flat portion 36 of the support plate 25 and the substrate 26 is shorter than the distance between the protrusion 37 of the support plate 25 and the substrate 26.

  The plurality of electric devices 17 include an electric device 17C provided at a position facing the flat portion 36 and electric devices 17A and 17B provided at a position facing the protruding portion 37, and the height of the electric devices 17A and 17B is increased. The height is higher than the height of the electric device 17C.

  In other words, a tall electrical device can be arranged on the lower surface 50 in a portion facing the protrusion 37.

  The bobbin 23 is arranged on the lower surface 19 of the support plate 25, and the ferrite plate 24 is arranged between the lower surface 19 of the support plate 25 and the upper surface 53 of the bobbin 23.

  The power receiving coil 8 is housed in a coil groove 43 formed on the lower surface 52, and the resin lid 22 is disposed on the lower surface 52 side of the bobbin 23.

  The resin support shaft 58 has a lower end connected to the main plate 55, and extends from the main plate 55 toward the pedestal 60 of the top plate 30. The resin support shaft 58 passes through the hollow portion 49 of the power receiving coil 8, the hollow portion 54 of the bobbin 23, the hollow portion 51 of the ferrite plate 24, the hole 40 of the support plate 25, and the hole 71 of the substrate 26, and Is supported by the pedestal 60.

  When the vehicle 2 equipped with the coil unit 4 configured as described above travels on an uneven road surface such as a rocky road, the coil unit 4 may come into contact with the ground (rock).

  At this time, the external force applied near the center of the resin lid 22 is supported by the resin support shaft 58, and the deformation of the coil unit 4 can be suppressed. Further, at a position apart from the center of the resin lid 22, the load applied to the resin lid 22 is supported by the support wall 32 through the main plate 55, the bobbin 23, and the support plate 25.

  As described above, even if the coil unit 4 comes into contact with the ground or the like, the coil unit 4 is suppressed from being greatly deformed, and the ferrite plate 24 and the electric device 17 can be prevented from being damaged. The support portion 64 supports the flat portion 36 of the support plate 25 on which the power receiving coil 8 and the ferrite plate 24 are arranged, and suppresses the flat portion 36 from being deformed. Since the deformation of the flat portion 36 is suppressed, it is possible to prevent the ferrite plate 24 arranged on the flat portion 36 from breaking or the power receiving coil 8 from being significantly deformed.

  Here, the resin support shaft 58 penetrates the protruding portion 37, and a plurality of high electrical devices 17 </ b> A and 17 </ b> B are arranged in a portion of the substrate 26 facing the protruding portion 37.

  Since the resin support shaft 58 is made of resin, it is not necessary to secure a creepage distance between the electric devices 17A and 17B, and the electric devices 17A and 17B can be arranged close to the resin support shaft 58.

  If, instead of the resin support shaft 58, a metal support shaft projecting downward from the top plate portion 30 and supporting the main plate 55 is provided, the metal support shaft and the electric devices 17A and 17B are connected to each other. It is necessary to secure a creepage distance between the two. On the other hand, since the resin support shaft 58 is a resin member, there is no need to provide a creepage distance between the resin support shaft 58 and the electric devices 17A and 17B, and the electric devices 17A and 17B are brought close to the resin support shaft 58. Can be arranged.

  As described above, in the coil unit 4 according to the present embodiment, members in the coil unit 4 and the electric device 17 can be protected from external loads, and a wide mounting space for the electric device 17 can be ensured. Can be. In the above example, the resin support shaft 58 is formed so as to pass through the hollow portion 49 of the power receiving coil 8. However, it is not essential that the resin support shaft 58 be disposed so as to pass through the hollow portion 49.

  In the above embodiment, the coil unit 4 mounted on the vehicle 2 has been described. However, the present invention can be applied to the coil unit 3 on the power transmission device side. It should be understood that the embodiments disclosed this time are illustrative in all aspects and not restrictive. The scope of the present invention is defined by the terms of the claims, rather than the description above, and is intended to include any modifications within the scope and meaning equivalent to the terms of the claims.

  DESCRIPTION OF SYMBOLS 1 Non-contact charging system, 2 vehicles, 3, 4 coil units, 5, 14 resonators, 6 rectifiers, 7 batteries, 8 receiving coils, 9, 13 capacitors, 10 power supplies, 11 converters, 12 transmitting coils, 15 floor panels , 16 pins, 17, 17A, 17B, 17C electrical equipment, 18, 44, 53, 70 upper surface, 19, 33, 45, 50, 52 lower surface, 20 housing case, 21 case body, 22 resin cover, 23 bobbin, 24 Ferrite plate, 24A split ferrite plate, 25 support plate, 26 substrate, 27, 46 overhang, 28, 35 screw hole, 29 slit, 30 top plate, 31 annular wall, 32 support wall, 34, 60, 61 Pedestal, 36 flat part, 37 projecting part, 38 boss, 39, 40, 47, 71 hole, 42, 48 bolt, 43 coil groove, 4 , 51 and 54 hollow portion 55 main plate, 56 a peripheral wall portion, 57 collar part, 58 a resin support shaft 62, 63, 64 support part, O1 turn of the rolling axis, TD thickness direction.

Claims (1)

A case in which a metal case main body disposed on an external fixing member and a resin lid provided to cover the case main body, and a housing space is formed therein,
An electric element housed in the case,
A support plate that includes a first main surface facing the case main body and a second main surface located on the opposite side of the first main surface, and is accommodated in the case;
A ferrite disposed on the second main surface of the support plate;
A spiral coil in which a hollow portion is formed while being disposed on the ferrite,
With
The case main body includes a metal supporting portion made of metal for supporting a portion of the first main surface facing the coil,
The lid includes a main plate, and a resin support portion made of resin formed to extend from the main plate toward the case body,
A coil unit, wherein one end of the resin support is supported by the case body.

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