WO2010038326A1

WO2010038326A1 - Noncontact power transfer apparatus, method for manufacturing noncontact power transfer apparatus, and vehicle equipped with noncontact power transfer apparatus

Info

Publication number: WO2010038326A1
Application number: PCT/JP2008/073212
Authority: WO
Inventors: 山本　幸宏; 和良高田; 慎平迫田
Original assignee: トヨタ自動車株式会社; 株式会社豊田自動織機
Priority date: 2008-10-01
Filing date: 2008-12-19
Publication date: 2010-04-08
Also published as: JP2010087353A

Abstract

A noncontact power receiving apparatus has a secondary self-resonant coil (110) capable of at least transmitting or receiving of power to or from a primary self-resonance coil disposed to face the noncontact power receiving apparatus by the resonance of a magnetic field, and a hollow bobbin (402) which holds the secondary self-resonant coil (110) along the inner peripheral surface thereof.

Description

Non-contact power transmission device, method for manufacturing non-contact power transmission device, and vehicle equipped with non-contact power transmission device

The present invention relates to a non-contact power transmission device, a method for manufacturing a non-contact power transmission device, and a vehicle including the non-contact power transmission device, and more particularly, a non-contact power that can receive power from a power source provided outside the vehicle in a non-contact manner. The present invention relates to a contact power transmission device and a vehicle.

電動 Electric vehicles such as electric cars and hybrid cars are attracting a great deal of attention as environmentally friendly vehicles. These vehicles are equipped with an electric motor that generates driving force and a rechargeable power storage device that stores electric power supplied to the electric motor. Note that the hybrid vehicle is a vehicle in which an internal combustion engine is further mounted as a power source together with an electric motor, or a fuel cell is further mounted as a direct current power source for driving the vehicle together with a power storage device.

Also in a hybrid vehicle, a vehicle capable of charging an in-vehicle power storage device from a power source external to the vehicle is known in the same manner as an electric vehicle. For example, a so-called “plug-in hybrid vehicle” that can charge a power storage device from a general household power supply by connecting a power outlet provided in a house and a charging port provided in the vehicle with a charging cable is known. Yes.

On the other hand, as a power transmission method, wireless power transmission that does not use a power cord or a power transmission cable has recently attracted attention. As this wireless power transmission technology, three technologies known as power transmission using electromagnetic induction, power transmission using electromagnetic waves, and power transmission using a resonance method are known.

Among them, the resonance method is a non-contact power transmission technique in which a pair of resonators (for example, a pair of self-resonant coils) are resonated in an electromagnetic field (near field) and transmitted through the electromagnetic field. It is also possible to transmit power over a long distance (for example, several meters) (see Non-Patent Document 1 and Patent Document 3).

Examples of the non-contact power feeding device that performs power transmission based on the mutual dielectric action of electromagnetic induction include the non-contact power feeding device described in Japanese Patent Application Laid-Open No. 2008-87733.

This contactless power supply device supplies power from the primary coil on the power supply side to the secondary coil on the power reception side based on the mutual dielectric action of electromagnetic induction. The primary coil and the secondary coil have a structure in which a plurality of parallel conductors are spirally wound on the same surface as a set, and are twisted at a constant pitch. The primary magnetic core and the secondary magnetic core where the primary coil and the secondary coil are disposed are made of ferrite or the like, and are formed in a flat plate shape. The surfaces of the primary coil and the primary magnetic core and the surfaces of the secondary coil and the secondary magnetic core are covered and fixed with a mold resin, respectively.

In addition, as a technique approximate to the wireless power transmission technique, for example, a technique related to a wireless portable device and an antenna of the wireless portable device described in JP-A-10-341105 is cited.

The antenna device described in Japanese Patent Laid-Open No. 10-341105 is provided on a cylindrical bobbin having a smooth inner peripheral surface and an outer peripheral surface of the bobbin, and has an impedance characteristic corresponding to a desired first frequency. And a first coil. Further, the antenna device includes a top plate that slides on the inner peripheral surface of the bobbin, an adjustment knob that rotates integrally with the top plate on the upper surface side of the top plate, and a desired second on the lower surface side of the adjustment knob. And a second coil having impedance characteristics corresponding to the frequency of the first, and a cover is provided so as to cover the first coil and the bobbin.
Andre Kurs et al., "Wireless Power Transfer via Strongly Coupled Magnetic Resonances" [online], July 6, 2007, SCIENCE, Vol. 317, p. 83-86, [Search September 12, 2007], Internet <URL: http://www.sciencemag.org/cgi/reprint/317/5834/83.pdf> JP 2008-87733 A Japanese Patent Laid-Open No. 10-341105 International Publication No. 2007/008646 Pamphlet

The non-contact power feeding apparatus using the resonance method includes a secondary self-resonant coil that receives power by resonating with a primary self-resonant coil provided outside. The primary self-resonant coil and the secondary self-resonant coil are configured by winding a winding around an outer surface of a bobbin. Since a high-voltage alternating current flows through each primary self-resonant coil and secondary self-resonant coil, it is necessary to provide a cover that covers the bobbin and the winding in order to protect each winding from the outside. As a result, many parts such as a bobbin and a cover are required.

Similarly, in the antenna device described in JP-A-10-341105, a cover is disposed so as to cover the first coil and the bobbin.

In the non-contact power feeding device described in Japanese Patent Laid-Open No. 2008-87733, both the primary coil and the secondary coil are covered with resin.

Therefore, a capacitor is formed by the resin material located between the windings of the primary coil and the secondary coil and between the windings. When an alternating current flows through each coil winding, dielectric loss due to the capacitor occurs, and the power transmission and power reception efficiency decreases.

The present invention has been made in view of the problems as described above, and an object thereof is a non-contact power transmission device in which the number of components is reduced and power transmission and power reception efficiency are improved, and this non-contact power transmission device The manufacturing method of this and the vehicle provided with this non-contact electric power transmission apparatus are provided.

A non-contact power transmission device according to the present invention includes a second self-resonant coil capable of transmitting and receiving power by resonance of a magnetic field with a first self-resonant coil arranged oppositely, and a hollow shape. And a bobbin having a second self-resonant coil held along the inner peripheral surface.

Preferably, the second self-resonant coil and the dielectric coil are mounted on the vehicle, the first self-resonant coil is disposed outside the vehicle, the first self-resonant coil transmits power to the second self-resonant coil, and the second The self-resonant coil receives power transmitted from the first self-resonant coil, and the second self-resonant coil and the dielectric coil constitute at least a part of the power receiving device.

Preferably, the first self-resonant coil is mounted on the vehicle, the second self-resonant coil and the dielectric coil are disposed outside the vehicle, the second self-resonant coil transmits power to the first self-resonant coil, and the first The self-resonant coil receives power transmitted from the second self-resonant coil, and the second self-resonant coil and the dielectric coil constitute at least a part of the power transmission device.

Preferably, the second self-resonant coil includes a first engagement portion, and the bobbin has a second engagement portion capable of locking the second self-resonance coil by engaging with the first engagement portion. Including. The first engaging portion and the second engaging portion can be engaged with each other by the elastic force of the second self-resonant coil.

Preferably, the inner peripheral surface of the bobbin is formed with a groove portion that extends in the axial direction of the bobbin and can receive the second self-resonant coil as it goes in the circumferential direction of the bobbin, and defines the groove portion. A coil locking portion that locks the second self-resonant coil received in the groove is formed on the inner peripheral surface of the.

Preferably, the inner peripheral surface of the bobbin is formed such that the length in the circumferential direction of the inner peripheral surface of the bobbin decreases from one end side to the other end of the bobbin. The inner peripheral surface of the bobbin is formed with a groove that extends in the axial direction of the bobbin as it goes in the circumferential direction of the bobbin and can receive the second self-resonant coil. Are arranged in the axial direction.

Preferably, the bobbin is formed in a bottomed cylindrical shape, and a housing portion that houses the second self-resonant coil is partitioned from the outside. Preferably, the bobbin is housed inside and further includes a shield member capable of defining a magnetic field radiation region.

A method for manufacturing a non-contact power transmission device according to the present invention includes a step of preparing a bobbin formed in a cylindrical shape, a second self-resonant coil having a reduced diameter by applying a load from the outside, and the second reduced diameter. The step of inserting the self-resonant coil into the bobbin and the load applied to the secondary self-resonant coil are removed, and the second self-resonant coil is locked into the bobbin using the elastic force of the second self-resonant coil. A process.

In another aspect of the method for manufacturing a non-contact power transmission device according to the present invention, an insulating plate-like member having a main surface, and one provided on the main surface and arranged in the extending direction of the plate-like member And a plurality of conductors arranged at intervals between one side portion and the other side portion arranged in the width direction of the plate-like member, while extending from one end portion to the other end portion. The plate member is curved so that the main surface on which the conductive wire is disposed is located on the inner side, and one end side of the plate member and the other end side are brought close to or in contact with each other. A step of bringing the end of the other side close to or in contact with the end of the other side of the other conducting wire adjacent to the side of the conducting wire, and the ends of the conducting wires. Forming a second self-resonant coil by connecting.

Preferably, the conductive wires are arranged at equal intervals from each other, and the lengths of one end side and the other end side are formed to coincide with each other, and one end side is the other end side. In the arrangement direction of the conductors, the conductors are positioned so as to be shifted by the interval length of the conductors.

A vehicle according to the present invention includes a rechargeable battery and the non-contact power transmission device according to any one of claims 1 to 6, and uses the non-contact power transmission device. The battery can be charged.

According to the non-contact power transmission device and the vehicle equipped with the non-contact power transmission device according to the present invention, the number of parts can be reduced and power transmission and power reception efficiency can be improved.

1 is an overall configuration diagram of a power feeding system according to Embodiment 1 of the present invention. It is a figure for demonstrating the principle of the power transmission by the resonance method. It is the figure which showed the relationship between the distance from an electric current source (magnetic current source), and the intensity | strength of an electromagnetic field. It is sectional drawing of a non-contact power receiving apparatus. It is a perspective view of the bobbin which visualized the inside partially. It is a perspective view of a secondary self-resonant coil. It is a sectional view of a part of the bobbin. FIG. 8 is a cross-sectional view taken along line VIII-VIII in FIG. It is sectional drawing which shows the 1st process of the manufacturing process of a non-contact power receiving apparatus. It is sectional drawing which shows the 2nd process of the manufacturing process of a non-contact power receiving apparatus. It is sectional drawing which shows the 3rd process of the manufacturing process of a non-contact power receiving apparatus. It is sectional drawing which shows the modification of a bobbin. FIG. 13 is a cross-sectional view in which a part of FIG. 12 is enlarged. It is sectional drawing which shows schematic structure of the injection molding machine which shape | molds a bobbin. It is sectional drawing of the bobbin which shows the other example of a bobbin. FIG. 16 is a cross-sectional view in which a part of FIG. 15 is enlarged. It is a perspective view of the bobbin provided in the non-contact electric power receiving apparatus which concerns on Embodiment 2 of this invention. It is a perspective view which shows the 1st process of the manufacturing process of a non-contact power receiving apparatus. It is a perspective view which shows the 2nd process of the manufacturing process of a non-contact power receiving apparatus. It is a perspective view which shows the 3rd process of the manufacturing process of a non-contact power receiving apparatus. It is a perspective view which shows the 4th process of the manufacturing process of a non-contact power receiving apparatus. It is a top view of the plate-shaped member for demonstrating the other manufacturing method of a non-contact electric power receiving apparatus. It is sectional drawing which shows a part of electric power feeder.

Explanation of symbols

100 electric vehicle, 110 secondary self-resonant coil, 120 secondary coil, 130 rectifier, 140 converter, 150 power storage device, 170 motor, 190 communication device, 200 power supply device, 210 AC power supply, 220 high frequency power driver, 230 primary coil, 240 primary self-resonant coil, 250 communication device, 310 high frequency power supply, 320 primary coil, 330 primary self-resonant coil, 340 secondary self-resonant coil, 350 secondary coil, 360 load, 400 power receiving device, 401 shield, 402 bobbin, 403 Fixed member, 404 support member, 405 connector, 410 top plate portion, 411 peripheral wall portion, 412 collar, 413 top plate portion, 414 opening portion, 415 peripheral wall portion, 416 bottom portion, 417 opening portion, 418 closing member, 4 0 coil receiving groove, 421 locking groove 422 engagement portion, 423 bottom 430 locking portion.

Hereinafter, embodiments of the present invention will be described in detail with reference to the drawings. In the drawings, the same or corresponding parts are denoted by the same reference numerals and description thereof will not be repeated.

(Embodiment 1)
1 is an overall configuration diagram of a power feeding system according to Embodiment 1 of the present invention. Referring to FIG. 1, the power feeding system includes a power receiving device (non-contact power transmission device) and a power feeding device (non-contact power transmission device) 200 provided in electric vehicle 100. Power receiving device provided in electrically powered vehicle 100 includes a secondary self-resonant coil 110, a secondary coil 120, a rectifier 130, a DC / DC converter 140, and a power storage device 150. Electric vehicle 100 includes a power receiving device, a power control unit (hereinafter also referred to as “PCU (Power Control Unit)”) 160, a motor 170, a vehicle ECU (Electronic Control Unit) 180, and a communication device 190. In addition.

The secondary self-resonant coil 110 is disposed at the lower part of the vehicle body, but may be disposed at the upper part of the vehicle body as long as the power feeding device 200 is disposed above the vehicle. The secondary self-resonant coil 110 is an LC resonant coil whose both ends are open (not connected), and receives power from the power feeder 200 by resonating with a primary self-resonant coil 240 (described later) of the power feeder 200 via an electromagnetic field. To do. The capacitance component of the secondary self-resonant coil 110 is the stray capacitance of the coil, but capacitors connected to both ends of the coil may be provided.

The secondary self-resonant coil 110 and the secondary self-resonant coil 240 are connected to the primary self-resonant coil 240 and the secondary self-resonant coil 240 based on the distance from the primary self-resonant coil 240 and the resonance frequency of the primary self-resonant coil 240 and the secondary self-resonant coil 110. The number of turns is appropriately set so that the Q value (for example, Q> 100) indicating the resonance intensity with the self-resonant coil 110 and κ indicating the degree of coupling increase.

The secondary coil 120 is disposed coaxially with the secondary self-resonant coil 110 and can be magnetically coupled to the secondary self-resonant coil 110 by electromagnetic induction. The secondary coil 120 takes out the electric power received by the secondary self-resonant coil 110 by electromagnetic induction and outputs it to the rectifier 130. The rectifier 130 rectifies the AC power extracted by the secondary coil 120.

DC / DC converter 140 converts the power rectified by rectifier 130 into a voltage level of power storage device 150 based on a control signal from vehicle ECU 180 and outputs the voltage level to power storage device 150. When power is received from power supply device 200 while the vehicle is traveling (in that case, power supply device 200 may be disposed above or to the side of the vehicle, for example), DC / DC converter 140 includes a rectifier. The power rectified by 130 may be converted into a system voltage and supplied directly to the PCU 160. DC / DC converter 140 is not necessarily required, and the AC power extracted by secondary coil 120 may be directly rectified by rectifier 130 and then directly supplied to power storage device 150.

The power storage device 150 is a rechargeable DC power source and includes, for example, a secondary battery such as lithium ion or nickel metal hydride. The power storage device 150 stores power supplied from the DC / DC converter 140 and also stores regenerative power generated by the motor 170. Then, power storage device 150 supplies the stored power to PCU 160. Note that a large-capacity capacitor can also be used as the power storage device 150, and is a power buffer that can temporarily store the power supplied from the power supply device 200 and the regenerative power from the motor 170 and supply the stored power to the PCU 160. Anything is acceptable.

The PCU 160 drives the motor 170 with power output from the power storage device 150 or power directly supplied from the DC / DC converter 140. PCU 160 also rectifies the regenerative power generated by motor 170 and outputs the rectified power to power storage device 150 to charge power storage device 150. The motor 170 is driven by the PCU 160 to generate a vehicle driving force and output it to driving wheels. Motor 170 generates electricity using kinetic energy received from driving wheels or an engine (not shown), and outputs the generated regenerative power to PCU 160.

The vehicle ECU 180 controls the PCU 160 based on the traveling state of the vehicle and the state of charge of the power storage device 150 (hereinafter also referred to as “SOC (State Of Charge)”) when the vehicle is traveling. Communication device 190 is a communication interface for performing wireless communication with power supply device 200 outside the vehicle.

Meanwhile, power supply apparatus 200 includes AC power supply 210, high-frequency power driver 220, primary coil 230, primary self-resonant coil 240, communication apparatus 250, and ECU 260.

AC power supply 210 is a power supply external to the vehicle, for example, a system power supply. The high frequency power driver 220 converts power received from the AC power source 210 into high frequency power, and supplies the converted high frequency power to the primary coil 230. Note that the frequency of the high-frequency power generated by the high-frequency power driver 220 is, for example, 1 M to several tens of MHz.

The primary coil 230 is disposed coaxially with the primary self-resonant coil 240, and can be magnetically coupled to the primary self-resonant coil 240 by electromagnetic induction. The primary coil 230 feeds high-frequency power supplied from the high-frequency power driver 220 to the primary self-resonant coil 240 by electromagnetic induction.

The primary self-resonant coil 240 is disposed near the ground, but may be disposed above the vehicle when power is supplied to the electric vehicle 100 from above the vehicle. The primary self-resonant coil 240 is also an LC resonant coil whose both ends are open (not connected), and transmits electric power to the electric vehicle 100 by resonating with the secondary self-resonant coil 110 of the electric vehicle 100 via an electromagnetic field. The capacitance component of the primary self-resonant coil 240 is also the stray capacitance of the coil, but capacitors connected to both ends of the coil may be provided.

The primary self-resonant coil 240 also has a Q value (for example, Q> based on the distance from the secondary self-resonant coil 110 of the electric vehicle 100, the resonance frequency of the primary self-resonant coil 240 and the secondary self-resonant coil 110, etc. 100), and the number of turns is appropriately set so that the degree of coupling κ and the like are increased.

The communication device 250 is a communication interface for performing wireless communication with the electric powered vehicle 100 that is a power supply destination. The ECU 260 controls the high frequency power driver 220 so that the received power of the electric vehicle 100 becomes a target value. Specifically, ECU 260 acquires the received power of electric vehicle 100 and its target value from electric vehicle 100 by communication device 250, and outputs high-frequency power driver 220 so that the received power of electric vehicle 100 matches the target value. To control. In addition, ECU 260 can transmit the impedance value of power supply apparatus 200 to electrically powered vehicle 100.

FIG. 2 is a diagram for explaining the principle of power transmission by the resonance method. Referring to FIG. 2, in this resonance method, in the same way as two tuning forks resonate, two LC resonance coils having the same natural frequency resonate in an electromagnetic field (near field), and thereby, from one coil. Electric power is transmitted to the other coil via an electromagnetic field.

Specifically, the primary coil 320 is connected to the high-frequency power source 310, and high-frequency power of 1 to 10 MHz is fed to the primary self-resonant coil 330 that is magnetically coupled to the primary coil 320 by electromagnetic induction. The primary self-resonant coil 330 is an LC resonator having an inductance and stray capacitance of the coil itself, and resonates with a secondary self-resonant coil 340 having the same resonance frequency as the primary self-resonant coil 330 via an electromagnetic field (near field). . Then, energy (electric power) moves from the primary self-resonant coil 330 to the secondary self-resonant coil 340 via the electromagnetic field. The energy (electric power) transferred to the secondary self-resonant coil 340 is taken out by the secondary coil 350 magnetically coupled to the secondary self-resonant coil 340 by electromagnetic induction and supplied to the load 360. Note that power transmission by the resonance method is realized when the Q value indicating the resonance intensity between the primary self-resonant coil 330 and the secondary self-resonant coil 340 is greater than 100, for example.

1 will be described. The AC power supply 210 and the high-frequency power driver 220 in FIG. 1 correspond to the high-frequency power supply 310 in FIG. Further, the primary coil 230 and the primary self-resonant coil 240 in FIG. 1 correspond to the primary coil 320 and the primary self-resonant coil 330 in FIG. 2, respectively, and the secondary self-resonant coil 110 and the secondary coil 120 in FIG. This corresponds to the secondary self-resonant coil 340 and the secondary coil 350 in FIG. In addition, the rectifier 130 and the subsequent parts in FIG.

FIG. 3 is a diagram showing the relationship between the distance from the current source (magnetic current source) and the strength of the electromagnetic field. Referring to FIG. 3, the electromagnetic field includes three components. A curve k1 is a component inversely proportional to the distance from the wave source, and is referred to as a “radiating electric field”. A curve k2 is a component inversely proportional to the square of the distance from the wave source, and is referred to as an “induced electric field”. The curve k3 is a component that is inversely proportional to the cube of the distance from the wave source, and is referred to as an “electrostatic field”.

The “electrostatic field” is a region where the intensity of the electromagnetic wave suddenly decreases with the distance from the wave source. In the resonance method, energy (electric power) is utilized using the near field (evanescent field) in which this “electrostatic field” is dominant. Is transmitted. That is, by resonating a pair of resonators having the same natural frequency (for example, a pair of LC resonance coils) in a near field where the “electrostatic field” is dominant, the resonance from one resonator (primary self-resonance coil) to the other Energy (electric power) is transmitted to the resonator (secondary self-resonant coil). Since this “electrostatic field” does not propagate energy far away, the resonance method can transmit power with less energy loss than electromagnetic waves that transmit energy (electric power) by “radiant electric field” that propagates energy far away. it can.

FIG. 4 is a cross-sectional view of the power receiving device 400, and FIG. 5 is a perspective view of the bobbin 402 with the inside partially visualized. As shown in FIGS. 4 and 5, the power receiving device 400 includes a secondary self-resonant coil 110, a secondary coil 120, a bobbin 402 that supports the secondary self-resonant coil 110, and a shield 401 that houses the bobbin 402. And.

The bobbin 402 is formed in a bottomed cylindrical shape, and an accommodating portion capable of accommodating the secondary self-resonant coil 110 is defined therein. And the accommodating part in the bobbin 402 is divided from the exterior by arrange | positioning an opening part side toward the floor panel side of the electric vehicle 100. FIG.

The secondary self-resonant coil 110 is supported and fixed in the bobbin 402, and exposure of the secondary self-resonant coil 110 to the outside is suppressed. As described above, the bobbin 402 not only supports the secondary self-resonant coil 110 but also has a function as a cover that covers the secondary self-resonant coil 110, and can reduce the number of parts.

The bobbin 402 has a top plate portion 410 arranged toward the primary self-resonant coil 240 at the time of power reception, a peripheral wall portion 411 depending from the peripheral portion of the top plate portion 410, and an opening 417 defined by the peripheral wall portion 411. And an eaves part 412 formed at the opening edge.

The top plate portion 410 is formed at the end portion of the bobbin 402 that faces the primary self-resonant coil 240 when receiving power, and separates the housing portion that houses the secondary self-resonant coil 110 from the outside. Yes. Thus, for example, even when the shield 401 is not provided, the secondary self-resonant coil 110 can be prevented from being exposed to the outside, and adverse effects such as adhesion of foreign matter to the secondary self-resonant coil 110 can be suppressed. can do.

The flange portion 412 is formed so as to protrude outward from the opening edge portion of the opening portion 417, and the flange portion 412 includes a plurality of fixing members 403 for fixing the top plate portion 410 to the shield 401. It is connected.

The shield 401 is made of, for example, a metal material such as copper or a cloth or sponge containing a metal material, and is made of a material that can reflect electromagnetic waves generated between the secondary self-resonant coil 110 and the primary self-resonant coil 240. It is configured.

The shield 401 is formed in a hollow shape, and a bobbin 402 is accommodated therein. The shield 401 is connected to the top plate portion 413 that faces the primary self-resonant coil 240 at the time of power reception, the peripheral wall portion 415 that hangs downward from the outer peripheral edge portion of the top plate portion 413, and the end portion of the peripheral wall portion 415. And a bottom portion 416 provided.

The opening 414 of the top plate 413 is closed by an insulating closing member 418. The shield 401 is mounted on the floor panel of the electric vehicle 100 so that the closing member 418 faces downward.

For this reason, when the power receiving device 400 receives power, the electromagnetic wave generated by the secondary self-resonant coil 110 is radiated to the outside through the blocking member 418 (opening 414), and is radiated toward the electric vehicle 100 side. Is suppressed.

The secondary coil 120 is located on the opposite side of the closing member 418 with respect to the secondary self-resonant coil 110 and is connected to a connector 405 provided on the bottom 416.

The secondary coil 120 is supported and fixed by a support member 404 provided on the bottom 416.

In the example shown in FIG. 4, the secondary coil 120 is located on the side opposite to the closing member 418 with respect to the secondary self-resonant coil 110, but is not limited to this position, and the secondary self-resonant coil is not limited thereto. 110 may be provided on the closing member 418 side.

Here, the secondary self-resonant coil 110 and the bobbin 402 are fixed to the bottom portion 416, and the distance from the bottom portion 416 of the secondary coil 120 is also defined by the support member 404. Thus, both the secondary self-resonant coil 110 and the secondary coil 120 are fixed to the bottom part 416, and the distance from the bottom part 416 is defined.

As a result, the distance between the secondary coil 120 and the secondary self-resonant coil 110 can be accurately positioned, the resonant frequency of the secondary self-resonant coil 110 can be accurately set, and the power receiving efficiency can be improved. Improvements can be made.

The bobbin 402 is formed with a coil receiving groove 420 that receives at least a part of the secondary self-resonant coil 110 and can support the secondary self-resonant coil 110.

The coil housing groove 420 extends from the opening 417 side toward the top plate 410 as it goes in the circumferential direction of the bobbin 402, and is formed in a spiral shape.

FIG. 6 is a perspective view of the secondary self-resonant coil 110. As shown in FIG. 6, locking portions (first engaging portions) 430 are formed at both ends of the secondary self-resonant coil 110, and the locking portions 430 are formed of the secondary self-resonant coil 110. Is bent radially outward from the end of the.

7 is a partial cross-sectional view of the bobbin 402, and FIG. 8 is a cross-sectional view taken along the line VIII-VIII of FIG.

As shown in FIGS. 7 and 8, in the inner peripheral surface of the peripheral wall portion 411, the portions located at both ends of the coil housing groove 420 are provided with locking grooves (second grooves) that can be engaged with the locking portions 430. Engaging portion) 421 is formed. The locking groove 421 extends from the bottom of the coil housing groove (groove portion) 420 toward the radially outer side of the bobbin 402 and can receive the locking portion 430.

And the engaging part 430 formed in the both ends of the secondary self-resonant coil 110 engages with the inner surface of the surrounding wall part 411 which defines the engaging groove 421, respectively, so that the secondary self-resonant coil 110 is a bobbin. Locked in 402.

Here, in the secondary self-resonant coil 110, the diameter of the secondary self-resonant coil 110 is larger than the diameter of the inner surface of the bobbin 402 when no load is applied from the outside.

The secondary self-resonant coil 110 housed in the bobbin 402 is housed in the bobbin 402 in a reduced diameter state compared to the unloaded state. For this reason, the secondary self-resonant coil 110 accommodated in the bobbin 402 is about to expand in diameter, and due to this elastic force, the locking portion 430 of the secondary self-resonant coil 110 defines the locking groove 421. Is engaged with the inner surface.

In this way, the secondary self-resonant coil 110 can be locked in the bobbin 402 by using the elastic force of the secondary self-resonant coil 110, so that, for example, no other fixture or adhesive is required. The number of parts can be reduced.

Furthermore, unlike the conventional coil, the fixing adhesive does not enter between the secondary self-resonant coils 110 and suppresses the formation of a large capacitor between the coil wires of the secondary self-resonant coil 110. Can do. Thereby, suppression of heat generation and improvement of power reception efficiency can be achieved.

A method for manufacturing the power receiving device 400 configured as described above will be described with reference to FIGS.

FIG. 9 is a cross-sectional view illustrating a first step in the manufacturing process of the power receiving device 400. As shown in FIG. 9, a secondary self-resonant coil 110 and a bobbin 402 are prepared. At this time, the diameter of the secondary self-resonant coil 110 is larger than the opening diameter of the opening 417 of the bobbin 402.

FIG. 10 is a cross-sectional view showing a second step of the manufacturing process of power reception device 400. In the process shown in FIG. 10, first, the locking portion 430 of the secondary self-resonant coil 110 is gripped by a gripping device (not shown). Then, the gripping device deforms the secondary self-resonant coil 110 so that the diameter of the secondary self-resonant coil 110 is reduced in a state where the locking portion 430 is gripped. Then, the secondary self-resonant coil 110 is inserted into the bobbin 402 with the diameter reduced.

FIG. 11 is a cross-sectional view showing a third step of the manufacturing process of power reception device 400. As shown in FIG. 11, after the secondary self-resonant coil 110 having a reduced diameter is completely accommodated in the bobbin 402, the engaging portions 430 of the secondary self-resonant coil 110 are inserted into the engaging grooves 421. Thereafter, the secondary self-resonant coil 110 is accommodated in the coil accommodating groove 420 by the gripping device opening the secondary self-resonant coil 110.

Then, the bobbin 402 to which the secondary self-resonant coil 110 is attached is attached in the shield 401 to which the secondary coil 120 is attached. Thereafter, a closing member 418 is attached to the opening 414 of the shield 401 to close the opening 414.

FIG. 12 is a cross-sectional view showing a modification of the bobbin 402, and FIG. 13 is a cross-sectional view in which a part of FIG. 12 is enlarged. As shown in FIGS. 12 and 13, the circumferential length of the inner peripheral surface of the peripheral wall portion 411 is formed so as to decrease from the opening 417 side toward the top plate portion 410 side. Here, the bobbin 402 is molded using, for example, an injection molding machine shown in FIG.

FIG. 14 is a cross-sectional view showing a schematic configuration of an injection molding machine 460 that molds the bobbin 402. As shown in FIG. 14, the injection molding machine 460 includes an outer mold 461 in which a cavity 463 is formed, And an inner mold 462 in which a core portion 466 is formed.

A groove forming portion 465 extending in a spiral shape is formed on the outer peripheral surface of the core portion 466, and a resin passage 464 through which resin flows is formed in the core portion 466.

In forming the bobbin 402, first, the outer mold 461 and the inner mold 462 are bonded, and the core portion 466 is inserted into the cavity 463. Thereby, a space is defined between the inner surface of the cavity 463 and the core portion 466. Then, the resin is supplied from the resin passage 464 into the defined space. Thereafter, the filled resin is cooled, and the inner mold 462 is rotated away from the outer mold 461, and the molded product is taken out. And the bobbin 402 is shape | molded by forming the locking groove 421 in the inner surface of a molded article.

Here, the core part 466 is formed in a tapered shape from the base part side toward the tip part side, and the frictional force generated in the core part 466 when the core part 466 is retracted from the molded product is reduced. . As a result, sink (sink)
mark) and the like can be suppressed, and a molded product can be molded satisfactorily.

Furthermore, the circumferential length of the inner peripheral surface of the cavity 463 is formed so as to decrease from the opening side to the bottom side of the cavity 463. As a result, when the molded product is extruded from the cavity 463, the frictional force generated between the inner surface of the cavity 463 and the outer surface of the molded product can be reduced. The surface can be molded well.

Here, the groove forming portion 465 is formed so as to protrude from the surface of the core portion 466, and the height of each apex portion of each groove forming portion 465 is formed to coincide. Specifically, the apex portion of the upper groove forming portion 465 is located on virtual axis lines L1 and L2 that are parallel to the rotation axis O1 of the inner mold 462.

Accordingly, as shown in FIGS. 12 and 13, the bottom portion 423 of the coil housing groove 420 formed in the molded bobbin 402 is arranged in the direction of the central axis O <b> 2 of the bobbin 402. Specifically, the bottom 423 of the coil accommodation groove 420 is arranged on virtual axes L3 and L4 parallel to the rotation axis O1.

Therefore, when the secondary self-resonant coil 110 is installed in the coil housing groove 420, the diameter of the secondary self-resonant coil 110 is kept constant at any position. Thereby, by attaching the secondary self-resonant coil 110 to the coil housing groove 420, it is possible to suppress fluctuation of the resonance frequency of the secondary self-resonant coil 110.

15 is a cross-sectional view of a bobbin 402 showing another example of the bobbin 402, and FIG. 16 is a cross-sectional view in which a part of FIG. 15 is enlarged. As shown in FIGS. 15 and 16, an engaging portion (coil locking portion) that locks the secondary self-resonant coil 110 received in the coil receiving groove 420 at the opening edge of the coil receiving groove 420. 422 is formed. The engaging portion 422 extends along the coil housing groove 420 and projects from both sides of the opening edge of the coil housing groove 420 so as to narrow the opening area of the coil housing groove 420. The engagement portion 422 prevents the secondary self-resonant coil 110 from dropping from the coil housing groove 420.

Since the engaging portion 422 is made of resin, when the secondary self-resonant coil 110 is mounted in the coil housing groove 420, the secondary self-resonant coil 110 is pressed toward the coil housing groove 420. Thus, the engaging portion 422 can be deformed and the secondary self-resonant coil 110 can be mounted in the coil housing groove 420.

(Embodiment 2)
A contactless power receiving device according to Embodiment 2 of the present invention will be described with reference to FIGS. 17 to 22. Of the configurations shown in FIGS. 17 to 22, the same or corresponding components as those shown in FIGS. 1 to 16 may be denoted by the same reference numerals and description thereof may be omitted. .

FIG. 17 is a perspective view of the bobbin 402 provided in the power receiving device according to the second embodiment of the present invention. As shown in FIG. 17, the bobbin 402 includes a peripheral wall portion 411 formed by forming an insulating plate-like member into a cylindrical shape, and a top plate portion 410 attached to one end of the peripheral wall portion 411. And.

Further, a secondary self-resonant coil 110 configured by connecting a plurality of conductive wires to each other with solder is mounted on the inner peripheral surface of the peripheral wall portion 411. Also in the example shown in FIG. 17, the secondary self-resonant coil 110 is mounted in a bobbin 402 formed in a bottomed cylindrical shape. For this reason, the bobbin 402 has a function of holding the secondary self-resonant coil 110 and a function of protecting the secondary self-resonant coil 110 from the outside. Compared with a conventional coil having a bobbin and a cover, the bobbin 402 The number of points can be reduced.

The power receiving device according to the present embodiment will be described with reference to FIGS. FIG. 18 is a perspective view showing a first step in the manufacturing process of the non-contact power receiving apparatus. As shown in FIG. 18, an insulating plate-like member 450 having a plurality of conducting wires 435A to 435D mounted on the main surface is prepared.

The plate-like member 450 is formed in a rectangular shape (square shape), and the outer peripheral edge portion of the plate-like member 450 is an end side portion arranged in the longitudinal direction of the plate-like member 450 (the extending direction of the plate-like member 450). 436 and 437 and

side portions

438 and 439 arranged in the short direction of the plate-like member 450 (the width direction of the plate-like member 450).

On the main surface of the plate-like member 450, a plurality of conductive wires 435A to 435D extending from the end side portion 436 to the end side portion 437 are arranged at equal intervals at intervals in the width direction of the plate-like member 450. Has been. In the example shown in FIG. 18, four conductors 435A to 435D are arranged between the side part 438 and the side part 439, and the conductors 435A to 435D are connected to the

side parts

438 and 439, respectively. It arrange | positions so that it may become parallel with respect to.

On the main surface of the plate-like member 450, there are formed engaging portions for receiving the respective conductors 435A to 435D and latching the respective conductors 435A to 435D. The conductors 435A to 435D are formed on the plate-like member 450. It is held on the main surface. The method of holding the conductive wires 435A to 435D is not limited to the above example. For example, each conducting wire 435A to 435D is formed with an engaging portion that engages with an engaging groove formed in the plate-like member 450, and the engaging portion is engaged with the engaging groove, whereby each conducting wire 435A to 435D. May be held on the main surface of the plate-like member 450.

FIG. 19 is a perspective view showing a second step of the manufacturing process of the non-contact power receiving apparatus. As shown in FIG. 19, the plate-like member 450 is bent so that the end side portion 436 and the end side portion 437 are close to each other, and the conducting wires 435A to 435D are positioned inside. When the plate-like member 450 is bent, the plate-like member 450 may be bent while being heated from the outside.

FIG. 20 is a perspective view showing a third step of the manufacturing process of the non-contact power receiving device. As shown in FIG. 20, the end side portion 437 and the end side portion 436 are brought into contact with each other. At this time, the end portion on the end side portion 436 side of the conducting wire 435D contacts the end portion on the end side portion 437 side of the conducting wire 435C adjacent to the side portion 438 side with respect to the conducting wire 435D. Similarly, the ends of the conducting

wires

435C and 435B on the end side 436 side are in contact with the ends of the conducting

wires

435B and 435A adjacent to the side portion 438 side of the conducting

wires

435C and 435B. . Then, the ends that contact each other are connected by solder. Thereby, the secondary self-resonant coil 110 is formed.

The solder part 440 that connects the ends of the conductive wires 435A to 435D also connects the end side part 436 and the end side part 437 of the plate-like member 450. Thereby, the plate-shaped member 450 is formed in a cylindrical shape.

FIG. 21 is a perspective view showing a fourth step in the manufacturing process of the non-contact power receiving apparatus. As shown in FIG. 21, a part of the side part 439 and a part of the side part 438 are cut to form a peripheral wall part 411 in which the opening edge part is flush.

Thus, the bobbin 402 shown in FIG. 17 can be molded by forming the peripheral wall portion 411 and then bonding the top plate portion 410 to the side portion 438. In this manner, after forming the bobbin 402 having the secondary self-resonant coil 110 mounted therein, the bobbin 402 is mounted in the shield 401 as shown in FIG.

Thus, according to the manufacturing method of the non-contact power receiving device according to the second embodiment, the process of manufacturing the bobbin 402 and the process of manufacturing the secondary self-resonant coil 110 can be performed simultaneously. Can be reduced.

FIG. 22 is a plan view of a plate-like member 450 for explaining another manufacturing method of the non-contact power receiving apparatus. In the example shown in FIG. 22, the plate-like member 450 is formed to be a parallelogram, and the lengths of the end side part 436 and the end side part 437 are the same, and further, the end side The portion 436 and the end side portion 437 are positioned so as to be shifted from each other by the interval length of the conductive wires 435A to 435D.

The conductive wires 435A to 435D are disposed so as to be perpendicular to the end side portion 436 and the end side portion 437, and the conductive wires 435A to 435D are disposed at equal intervals in the width direction of the plate-like member 450.

In this way, the formed plate-like member 450 is bent, and the end side part 436 and the end side part 437 are brought into contact with each other. At this time, both end portions of the end side portion 436 and both end portions of the end side portion 437 are brought into contact with each other. Thereby, the peripheral wall part 411 in which the opening part was made flush is formed.

In addition, by bending the plate-like member 450 as described above, the ends of the conducting

wires

435D, 435C, and 435B are in contact with the ends of the conducting

wires

435C, 435B, and 435A on the end side 436 side or Proximity.

Then, by soldering the ends of each conductive wire, the secondary self-resonant coil 110 can be formed and the bobbin 402 can be formed.

In the first and second embodiments, the power receiving device 400 has been described. However, the present invention is not limited to this.

That is, as shown in FIG. 23, the present invention can also be applied to the bobbin that holds the primary self-resonant coil 240 and the primary coil 230 of the power feeding apparatus 200. In this case, the primary self-resonant coil 240 is attached to the inner peripheral surface of the bobbin 402 shown in FIG. 4, and the bobbin 402 and the primary self-resonant coil 240 to which the primary self-resonant coil 240 is attached are embedded in the ground, for example. .

And the non-contact power receiving device shown in each of the above embodiments can be mounted on various electric vehicles. The electric vehicle can be applied to other types of hybrid vehicles besides the series / parallel type hybrid vehicle in which the power of the engine can be divided and transmitted to the drive wheels and the motor generator by the power split device. That is, for example, a so-called series-type hybrid vehicle that uses an engine only to drive a motor generator and generates the driving force of the vehicle only by the motor generator, or only regenerative energy of the kinetic energy generated by the engine is electric energy. The present invention can also be applied to a hybrid vehicle that is recovered as a motor, a motor-assist type hybrid vehicle in which a motor assists the engine as the main power.

The present invention can also be applied to an electric vehicle that runs only on electric power without an engine, and a fuel cell vehicle that further includes a fuel cell as a DC power source in addition to a power storage device. The present invention is also applicable to an electric vehicle that does not include a boost converter.

The embodiment disclosed this time should be considered as illustrative in all points and not restrictive. The scope of the present invention is shown not by the above description of the embodiments but by the scope of claims, and is intended to include all modifications within the meaning and scope equivalent to the scope of claims.

The present invention can be applied to a non-contact power transmission device, a method for manufacturing the non-contact power transmission device, and a vehicle including the non-contact power transmission device. In particular, the power from a power source provided outside the vehicle is not connected. It is suitable for a non-contact power transmission device and a vehicle that can receive power.

Claims

A second self-resonant coil (110, 240) capable of at least one of transmitting and receiving electric power by resonance of a magnetic field with the first self-resonant coil (240, 110) arranged oppositely;
A bobbin (402) formed in a hollow shape and holding the second self-resonant coil along an inner peripheral surface;
A non-contact power transmission device.
The second self-resonant coil (110) and the dielectric coil (120) are mounted on a vehicle, the first self-resonant coil (240) is disposed outside the vehicle, and the first self-resonant coil is the second self-resonant coil. Electric power is transmitted to the resonance coil, the second self-resonance coil receives electric power transmitted from the first self-resonance coil, and the second self-resonance coil and the dielectric coil are at least part of the power receiving device (400). The non-contact power transmission device according to claim 1, comprising:
The first self-resonant coil (110) is mounted on the vehicle, the second self-resonant coil (240) and the dielectric coil (230) are disposed outside the vehicle, and the second self-resonant coil is the first self-resonant coil. Electric power is transmitted to the resonance coil, the first self-resonance coil receives electric power transmitted from the second self-resonance coil, and the second self-resonance coil and the dielectric coil are at least part of the power transmission device (200). The non-contact power transmission device according to claim 1, comprising:
The second self-resonant coil includes a first engagement part (430), and the bobbin (402) can engage with the first engagement part to lock the second self-resonance coil. Including a second engagement portion (421),
2. The non-contact power transmission device according to claim 1, wherein the first engagement portion and the second engagement portion can be engaged with each other by an elastic force of the second self-resonant coil.
A groove (420) is formed on the inner peripheral surface of the bobbin so as to extend in the axial direction of the bobbin as it goes in the circumferential direction of the bobbin and to receive the second self-resonant coil (110, 240). The coil locking portion (422) for locking the second self-resonant coil received in the groove portion is formed on the inner peripheral surface of the bobbin that defines the groove portion. The non-contact power transmission device according to item.
The inner peripheral surface of the bobbin is formed so that the length in the circumferential direction of the inner peripheral surface of the bobbin decreases from one end side to the other end of the bobbin,
On the inner peripheral surface of the bobbin, a groove (420) is formed that extends in the axial direction of the bobbin as it goes in the circumferential direction of the bobbin and can receive the second self-resonant coil.
The non-contact power transmission device according to claim 1, wherein the bottom of the groove is arranged in the axial direction (O2) of the bobbin.
The non-contact power transmission device according to claim 1, wherein the bobbin is formed in a bottomed cylindrical shape, and a housing portion that houses the second self-resonant coil is partitioned from the outside.
The non-contact power transmission device according to claim 1, further comprising a shield member (401) capable of accommodating the bobbin therein and defining a radiation region of the magnetic field.
Preparing a bobbin (402) formed in a cylindrical shape;
Reducing the diameter of the second self-resonant coil (110) by applying a load from the outside, and inserting the reduced second self-resonant coil into the bobbin;
Removing the load applied to the secondary self-resonant coil, and locking the second self-resonant coil in the bobbin using the elastic force of the second self-resonant coil;
The manufacturing method of the non-contact electric power transmission apparatus provided with.
An insulating plate-like member (450) having a main surface, and one end side (437) provided on the main surface and arranged in the extending direction of the plate-like member to the other end side (436) And a plurality of conductive wires (435A to 435D) arranged at intervals between one side portion and the other side portion arranged in the width direction of the plate-shaped member; and
The plate member is curved so that the main surface on which the conductor is disposed is located on the inner side, and one end side and the other end side of the plate member are brought close to or in contact with each other, and the conductor A step of bringing the end of the one side of the other side close to or in contact with the end of the other side of the other conducting wire adjacent to the side of the conducting wire;
Connecting the ends of the conducting wires to form a second self-resonant coil;
The manufacturing method of the non-contact electric power transmission apparatus provided with.
The conducting wires are arranged at equal intervals from each other,
The lengths of the one end side and the other end side are formed to coincide with each other,
The non-contact power transmission device according to claim 10, wherein the one end side portion is positioned so as to be shifted by an interval length of the conducting wires in the arrangement direction of the conducting wires with respect to the other end side portion. Manufacturing method.
A rechargeable battery (150);
A vehicle comprising the non-contact power transmission device according to claim 1 and capable of charging the battery using the non-contact power transmission device.