JP7622657B2 - Coil unit and method for manufacturing the coil unit - Google Patents

Description

The present invention relates to a coil unit including a support plate, a coil arranged along the support surface of the support plate, and molded resin, and to a method for manufacturing the coil unit.

For example, Japanese Patent No. 5958423 (Patent Document 1) discloses a coil unit used for contactless power supply to a forklift equipped with a battery. In the following description of the background art, the reference numerals in parentheses refer to those in Patent Document 1.

In the technology disclosed in Patent Document 1, a space is formed between the floor plate (5) and the side plate (8), and the coil (9, 10) and ferrite (7) are placed in this space and resin (17) is injected into it. As a result, the floor plate (5), side plate (8), coil (9, 10), and ferrite (7) are integrated with the resin (17) to form a coil unit.

Patent No. 5958423

However, in the technology disclosed in Patent Document 1, space-forming members such as a floor plate (5) and a side plate (8) are used to form a space for arranging the coil (9, 10), ferrite (7), and resin (17), and these floor plates (5) and side plates (8) become part of the completed coil unit. This increases the number of parts that make up the coil unit, which causes the problem of high costs.

In light of the above situation, it is desirable to realize a coil unit that can properly integrate the various components that make up the coil unit and that can easily achieve low costs.

A coil unit including a support plate, a coil disposed along a support surface of the support plate, and a mold resin,
The coil includes a first coil body and a second coil body that are each formed in an annular shape when viewed in a normal direction along the normal direction of the support surface, and that are arranged adjacent to each other in a first direction that is a specific direction along the support surface,
A direction perpendicular to the first direction when viewed in the normal direction is defined as a second direction,
each of the first coil body and the second coil body includes a curved portion formed in a portion facing each other in the first direction so as to move toward a side that moves away from each other in the first direction as the curved portion moves toward an outer side in the second direction;
a fixing member is disposed between the curved portion of the first coil body and the curved portion of the second coil body in the first direction;
the fixing member has a fixing portion fixed to the support plate and an extending portion arranged to extend from the fixing portion to a side where the first coil body and the second coil body are arranged with respect to the support surface,
The first coil body, the second coil body, and the extension portion are embedded in the molding resin, and the molding resin and the support plate are integrally joined together.

When a space forming member for forming a space in which a coil or molded resin is arranged is used as in the past, each member including the space forming member is joined to the molded resin, so that each member can be properly integrated. However, when forming a coil unit without using such a space forming member, it is necessary to properly integrate the molded resin and the member in contact with the molded resin. According to this configuration, the fixing portion of the fixing member is fixed to the support plate and the extension portion of the fixing member is embedded in the molded resin, so that the molded resin and the support plate can be properly integrated, and thus the first coil body and the second coil body embedded in the molded resin can be properly integrated with the support plate. Furthermore, according to this configuration, since the fixing member is disposed in the dead space between the curved portion of the first coil body and the curved portion of the second coil body in the first direction, the molded resin and the support plate can be properly integrated while suppressing the expansion of the dimensions of the coil unit. As described above, according to this configuration, each member constituting the coil unit can be properly integrated, and a coil unit that is easy to reduce costs can be realized.

A method for manufacturing a coil unit including a support plate, a coil, and a molding resin, comprising the steps of:
a coil arrangement step of arranging the coil including a first coil body and a second coil body along a support surface of the support plate, a fixing member arrangement step of arranging a fixing member, and a resin supply step of supplying a resin, which is performed after the coil arrangement step and the fixing member arrangement step,
In the coil arrangement step, the first coil body and the second coil body are each formed into an annular shape when viewed in a normal direction along the normal direction of the support surface, and the first coil body and the second coil body are arranged so as to be adjacent to each other in a first direction, which is a specific direction along the support surface;
A direction perpendicular to the first direction when viewed in the normal direction is defined as a second direction,
a curved portion is a portion of each of the first coil body and the second coil body that faces each other in the first direction and is formed so as to move toward a side that moves away from each other in the first direction as it moves toward an outer side in the second direction,
In the fixing member arrangement step, the fixing member is arranged between the curved portion of the first coil body and the curved portion of the second coil body in the first direction, a fixing portion of the fixing member is fixed to the support plate, and an extension portion extending from the fixing portion is arranged so as to extend on a side where the first coil body and the second coil body are arranged with respect to the support surface;
In the resin supplying step, the resin is supplied to an area adjacent to the support surface of the support plate so that the first coil body, the second coil body, and the extension portion are embedded in the resin.

According to this configuration, the fixing member is fixed to the support plate by the fixing portion in the fixing member arrangement process, and then the extension portion of the fixing member is embedded in the resin in the resin supply process, so that the molded resin formed by the hardening of the resin can be properly integrated with the support plate. This allows the first coil body and the second coil body embedded in the molded resin to be properly integrated with the support plate. Furthermore, according to this configuration, the fixing member is arranged in the dead space between the curved portion of the first coil body and the curved portion of the second coil body in the first direction, so that the molded resin can be properly integrated with the support plate while suppressing the increase in the dimensions of the coil unit. As described above, according to this configuration, it is possible to properly integrate each member constituting the coil unit and realize a coil unit that is easy to reduce costs.

Further features and advantages of the technology disclosed herein will become more apparent from the following description of exemplary, non-limiting embodiments, which are described with reference to the drawings.

Diagram showing an example of coil unit usage Normal view of coil unit 3 is a cross-sectional view taken along line III-III in FIG. Flowchart showing the manufacturing process of the coil unit 1 is a diagram showing a process of manufacturing the coil unit 100. 4 is a cross-sectional view of a coil unit according to another embodiment; 4 is a cross-sectional view of a coil unit according to another embodiment; 4 is a cross-sectional view of a coil unit according to another embodiment;

Below, an embodiment of the coil unit will be described with reference to the drawings. As shown in FIG. 1, the coil unit 100 is used as a non-contact power supply device that supplies power to an object without contact. In the non-contact power supply device, a power receiving coil unit 100 and a power transmitting coil unit 100 are used, and power is supplied to the object in a non-contact state by utilizing electromagnetic induction, in which an electromotive force is generated in the power receiving coil unit 100 by a magnetic field generated in the power transmitting coil unit 100.

Figure 1 shows an example of an article transport vehicle V equipped with a power storage device 9v being charged at a charging station S.

The goods transport vehicle V is an automatic guided vehicle (AGV) that is configured to automatically transport goods (not shown). The goods transport vehicle V is equipped with a power-receiving coil unit 100 that is electrically connected to the power storage device 9v.

The charging station S is provided with a power transmission coil unit 100 electrically connected to a power source 9s. Although detailed illustration is omitted, the power source 9s is configured as, for example, a high-frequency power supply device connected to a commercial power source.

The coil unit 100 on the power transmission side generates a magnetic field using power from the power source 9s. The coil unit 100 on the power receiving side generates an electromotive force using the magnetic field generated on the power transmission side. The power generated by the electromotive force is stored in the power storage device 9v and is used to operate the goods transport vehicle V.

In this way, the coil unit 100 is electrically connected to the target part 9. The coil unit 100 on the power receiving side is electrically connected to the power storage device 9v as the target part 9, and the coil unit 100 on the power transmitting side is electrically connected to the power source 9s as the target part 9. The coil unit 100 on the power transmitting side and the coil unit 100 on the power receiving side have the same configuration. The detailed configuration of the coil unit 100 will be described below.

As shown in Figures 2 and 3, the coil unit 100 includes a support plate 1, a coil 2 arranged along the support surface F1 of the support plate 1, and molded resin 3. The coil unit 100 further includes a core 5 made of a magnetic material. The coil unit 100 also includes a cover 6 that covers the coil 2, the core 5, and the molded resin 3. The cover 6 is connected to the support plate 1, and an inner-cover space 60 is formed between the support plate 1 and the cover 6. The coil 2, the core 5, and the molded resin 3 are arranged in the inner-cover space 60.

In the following, a specific direction along the support surface F1 of the support plate 1 is referred to as the "first direction X", and a direction perpendicular to the first direction X when viewed in the normal direction along the normal direction of the support surface F1 is referred to as the "second direction Y". As shown in FIG. 2, in this example, the support plate 1 is formed in a rectangular shape (including a shape that is approximately rectangular overall) when viewed in the normal direction, and the direction along its long side is referred to as the first direction X. Note that FIG. 2 shows the coil unit 100 when viewed in the normal direction. FIG. 3 shows a cross-sectional view taken along the III-III cross section in FIG. 2.

The support plate 1 supports the coil 2, the core 5, and the molded resin 3 on the support surface F1. In this embodiment, the support plate 1 is made of metal. For example, the support plate 1 is made of an aluminum plate.

In this embodiment, the support plate 1 comprises a metal plate member 10 (e.g., an aluminum plate) and an insulating sheet 11 (electrically insulating sheet).

The fixing member 4, which will be described later, is fixed to the support plate 1. The support plate 1 has a mounting hole 12 to which the fixing member 4 is attached. In this example, the mounting hole 12 has a female thread 12a formed therein.

The insulating sheet 11 is attached to the surface of the plate member 10. In this example, the surface of the insulating sheet 11 attached to the plate member 10 serves as the support surface F1. In other words, the coil 2, the core 5, and the molded resin 3 are supported on the surface of the insulating sheet 11 (support surface F1).

The coil 2 includes a first coil body 21 and a second coil body 22 that are each formed in a ring shape when viewed in a normal direction along the normal direction of the support surface F1 and are arranged adjacent to each other in a first direction X, which is a specific direction along the support surface F1. In this embodiment, each of the first coil body 21 and the second coil body 22 is formed by winding an insulating coated linear conductor in a ring shape. A portion of each of the first coil body 21 and the second coil body 22 is pulled out to the outside of the cover 6 and is electrically connected to the target portion 9 (the power storage device 9v on the power receiving side and the power source 9s on the power transmitting side).

As shown in FIG. 2, in this embodiment, the center position of the first coil body 21 when viewed in the normal direction (hereinafter referred to as the "first center position C1") and the center position of the second coil body 22 (hereinafter referred to as the "second center position C2") are located at the same position in the second direction Y.

The first center position C1 is a position set in the center of the area surrounded by the outer edge of the first coil body 21 when viewed in the normal direction. For example, the first center position C1 can be the center of gravity of the area surrounded by the outer edge of the first coil body 21 when viewed in the normal direction (the center of gravity of the figure when the area is viewed as a figure). Although different from the illustration, for example, the first center position C1 can also be the center position or center of gravity of the gap portion surrounded by the first coil body 21 when viewed in the normal direction. The second center position C2 is a position set in the center of the area surrounded by the outer edge of the second coil body 22 when viewed in the normal direction. For example, the second center position C2 can be the center of gravity of the area surrounded by the outer edge of the second coil body 22 when viewed in the normal direction (the center of gravity of the figure when the area is viewed as a figure). Although different from the illustration, for example, the second center position C2 can be the center position or center of gravity of the gap portion surrounded by the second coil body 22 when viewed in the normal direction.

In this embodiment, the outer edge portion 21E of the first coil body 21 (hereinafter referred to as the "first outer edge portion 21E") and the outer edge portion 22E of the second coil body 22 (hereinafter referred to as the "second outer edge portion 22E") when viewed in the normal direction are arranged at the same position in the second direction Y. The first outer edge portion 21E is the end portion of the first coil body 21 in the second direction Y. The second outer edge portion 22E is the end portion of the second coil body 22 in the second direction Y. The end portion of the first coil body 21 in the second direction Y (first outer edge portion 21E) and the end portion of the second coil body 22 in the second direction Y (second outer edge portion 22E) are arranged at the same position in the second direction Y. As a result, the first coil body 21 and the second coil body 22 are contained within the same region in the second direction Y. The above configuration makes it easier to miniaturize the entire coil unit 100 while ensuring the size of the first coil body 21 and the second coil body 22.

Each of the first coil body 21 and the second coil body 22 has curved portions (210, 220) formed in the portions facing each other in the first direction X so as to move toward the outside in the second direction Y and toward the side away from each other in the first direction X. In this embodiment, each of the first coil body 21 and the second coil body 22 has straight portions (211, 221) formed continuously with the curved portions (210, 220) and extending linearly along the second direction Y in the portions facing each other in the first direction X. The curved portions (210, 220) are portions formed in a curved shape when viewed in the normal direction. The straight portions (211, 221) are portions formed in a linear shape when viewed in the normal direction. Hereinafter, the curved portion 210 of the first coil body 21 will be referred to as the "first curved portion 210", and the curved portion 220 of the second coil body 22 will be referred to as the "second curved portion 220". In addition, the straight portion 211 of the first coil body 21 is referred to as the "first straight portion 211," and the straight portion 221 of the second coil body 22 is referred to as the "second straight portion 221."

The first straight portion 211 and the second straight portion 221 face each other in the first direction X. The first straight portion 211 is the portion of the first coil body 21 that is disposed closest to the second coil body 22. The second straight portion 221 is the portion of the second coil body 22 that is disposed closest to the first coil body 21. In this embodiment, the first straight portion 211 and the second straight portion 221 are disposed so as to be in contact with each other in the first direction X. This makes it possible to ensure a wide area occupied by the coil 2 in the space 60 inside the cover.

In this embodiment, a pair of first curved portions 210 are arranged on both sides of the first straight portion 211 in the second direction Y. Each of the pair of first curved portions 210 is arranged between the first straight portion 211 and the first outer edge portion 21E. In this example, the first coil body 21 has a shape that is line-symmetrical with respect to a virtual line L that connects the first center position C1 and the second center position C2 when viewed in the normal direction. Therefore, a part of the first straight portion 211, the first curved portion 210, and the first outer edge portion 21E are arranged on both sides of the virtual line L in the second direction Y.

In this embodiment, a pair of second curved portions 220 are arranged on both sides of the second straight portion 221 in the second direction Y. Each of the pair of second curved portions 220 is arranged between the second straight portion 221 and the second outer edge portion 22E. In this example, the second coil body 22 has a shape that is line-symmetrical with respect to a virtual line L that connects the first center position C1 and the second center position C2 when viewed in the normal direction. Therefore, a part of the second straight portion 221, the second curved portion 220, and the second outer edge portion 22E are arranged on both sides of the virtual line L in the second direction Y.

The first curved portion 210 is formed so that the closer the portion is to the second coil body 22, the further away it is from the outer edge of the support plate 1 (and the cover 6) in the second direction Y. In other words, the closer the portion is to the second coil body 22, the closer it is to the outer edge of the support plate 1 (and the cover 6) in the second direction Y.

In this embodiment, the first curved portion 210 includes a tapered section 210a that is continuous with the first outer edge portion 21E and inclines toward the center side (virtual line L) in the second direction Y as it approaches the second coil body 22, and an arc section 210b that is continuous with the tapered section 210a and is formed in an arc shape when viewed in the normal direction. The arc section 210b is continuous with the first straight portion 211 at the end opposite to the end that is continuous with the tapered section 210a. The arc section 210b is formed in an arc shape such that the center of the arc is on the side of the first center position C1.

The second curved portion 220 is formed so that the closer the portion is to the first coil body 21, the further away it is from the outer edge of the support plate 1 (and the cover 6) in the second direction Y. In other words, the closer the portion is to the first coil body 21, the closer it is to the outer edge of the support plate 1 (and the cover 6) in the second direction Y.

In this embodiment, the second curved portion 220 includes a tapered section 220a that is continuous with the second outer edge portion 22E and inclines toward the center side (virtual line L) in the second direction Y as it approaches the first coil body 21, and an arc section 220b that is continuous with the tapered section 220a and is formed in an arc shape when viewed in the normal direction. The arc section 220b is continuous with the second straight portion 221 at the end opposite to the end that is continuous with the tapered section 220a. The arc section 220b is formed in an arc shape such that the center of the arc is on the side of the second center position C2.

By arranging the first curved portion 210 and the second curved portion 220 configured as described above facing each other in the first direction X, a non-coil arrangement space in which the coil 2 is not arranged (hereinafter referred to as the "non-coil arrangement space Ga in the first direction X") is formed between the first curved portion 210 and the second curved portion 220 in the first direction X.

The first coil body 21 is formed by winding the linear conductor in a ring shape when viewed in the normal direction so that the dimension in the normal direction increases as the number of turns of the linear conductor increases. In other words, the first coil body 21 is formed by stacking the linear conductor wound in a ring shape in the normal direction. As shown in FIG. 5, in this embodiment, the first coil body 21 is formed so that the dimension in the normal direction decreases as the portion approaches the second coil body 22. As a result, in the portion of the first coil body 21 that approaches the second coil body 22, a coil non-arrangement space (hereinafter referred to as the "normal coil non-arrangement space Gb") in which the coil 2 is not arranged in the normal direction is formed. In this example, in the region on the second coil body 22 side of the first center position C1, each part in the normal direction of the linear conductor constituting the first coil body 21 is offset toward the second coil body 22 side in a hierarchical manner. As a result, the first coil body 21 is formed so that the dimension in the normal direction is smaller in the portion closer to the second coil body 22. Note that FIG. 5 shows the coil unit 100 in the middle of being manufactured, but the arrangement of the support plate 1, coil 2, core 5, and fixing member 4 in the finished coil unit 100 is as shown in FIG. 5.

The second coil body 22 is formed by winding the linear conductor in a ring shape when viewed in the normal direction so that the dimension in the normal direction increases as the number of turns of the linear conductor increases. In other words, the second coil body 22 is formed by stacking the linear conductor wound in a ring shape in the normal direction. In this embodiment, the second coil body 22 is formed so that the dimension in the normal direction decreases as the portion approaches the first coil body 21. As a result, in the portion of the second coil body 22 close to the first coil body 21, a coil non-arrangement space (normal coil non-arrangement space Gb) in which the coil 2 is not arranged in the normal direction is formed. In this example, in the region on the first coil body 21 side from the second center position C2, each part in the normal direction of the linear conductor constituting the second coil body 22 is offset toward the first coil body 21 side in a hierarchical manner. As a result, the second coil body 22 is formed so that the dimension in the normal direction decreases as the portion approaches the first coil body 21.

In this embodiment, a core 5 made of a magnetic material is disposed between the first coil body 21 and the second coil body 22 and the support plate 1. For example, the core 5 is made of a magnetic material made of ferrite. The core 5 may be made of a single magnetic material. Alternatively, one core 5 may be formed by combining multiple magnetic materials.

In this embodiment, the core 5 is continuously arranged in the first direction X so as to overlap both the first central position C1 and the second central position C2 when viewed in the normal direction. The core 5 has an overlapping portion 50 that overlaps with the coil 2 when viewed in the normal direction, and a non-overlapping portion (51, 52) that does not overlap with the coil 2 when viewed in the normal direction.

The overlapping portion 50 is the center of the core 5 in the first direction X. When viewed in the normal direction, the overlapping portion 50 overlaps both the first coil body 21 and the second coil body 22. As described above, in this embodiment, a non-coil arrangement space Gb in the normal direction is formed in the portion where the first coil body 21 and the second coil body 22 are close to each other (see FIG. 5). The overlapping portion 50 is disposed in the non-coil arrangement space Gb in the normal direction.

The non-overlapping portion (51, 52) is both ends of the core 5 in the first direction X. The non-overlapping portion (51, 52) includes a first non-overlapping portion 51 arranged closer to the first coil body 21 in the first direction X than the overlapping portion 50, and a second non-overlapping portion 52 arranged closer to the second coil body 22 in the first direction X than the overlapping portion 50. In this embodiment, the first non-overlapping portion 51 is arranged outside the first direction X from the first center position C1. Alternatively, a part of the first non-overlapping portion 51 may be arranged outside the first direction X from the first center position C1. Also, the second non-overlapping portion 52 is arranged outside the second center position C2 in the first direction X. Alternatively, a part of the second non-overlapping portion 52 may be arranged outside the second center position C2 in the first direction X.

As shown in Figures 2 and 3, in this embodiment, the core 5 is arranged so as to be in contact with the support surface F1. This makes it easier to transfer heat generated from the coil 2 to the support plate 1 via the core 5, which makes it easier to improve the heat dissipation of the coil unit 100. In this example, the entire surface of the core 5 that faces the support surface F1 is in contact with the support surface F1. This can further enhance the above-mentioned effect.

In the coil unit 100 according to the present disclosure, the fixing member 4 is disposed between the curved portion (first curved portion 210) of the first coil body 21 and the curved portion (second curved portion 220) of the second coil body 22 in the first direction X. The fixing member 4 is a member for fixing the molded resin 3 and the support plate 1. As described above, a coil non-arrangement space (coil non-arrangement space Ga in the first direction X) in which the coil 2 is not arranged is formed between the first curved portion 210 and the second curved portion 220 in the first direction X. The fixing member 4 is disposed in the coil non-arrangement space Ga in the first direction X. The fixing member 4 is configured using a non-magnetic material such as SUS, aluminum, synthetic resin, etc. This makes it difficult for the fixing member 4 to generate heat when a magnetic field is generated. In addition, the fixing member 4 can be disposed while minimizing the effect on the magnetic field generated by the coil 2.

In this embodiment, multiple fixed members 4 are provided. The multiple fixed members 4 are arranged line-symmetrically with respect to a virtual line L connecting the first center position C1 and the second center position C2 when viewed in the normal direction. The multiple fixed members 4 are arranged in the coil non-arrangement space Ga in the first direction X. In this example, two fixed members 4 are arranged line-symmetrically with respect to the virtual line L when viewed in the normal direction.

The fixed member 4 has a fixed portion 41 fixed to the support plate 1 and an extension portion 42 arranged to extend from the fixed portion 41 toward the side where the first coil body 21 and the second coil body 22 are arranged with respect to the support surface F1.

In this embodiment, the fixing portion 41 has a fixed side male threaded portion 411 arranged on the side of the support plate 1 of the fixing member 4. A male thread 411a is formed in the fixed side male threaded portion 411. The male thread 411a of the fixed side male threaded portion 411 is screwed into the female thread 12a formed in the mounting hole 12 of the support plate 1 and fixed. That is, in this embodiment, the male thread 411a formed in the fixing portion 41 is screwed into the female thread 12a formed in the support plate 1 and fixed.

The extension end 42E, which is the end of the extension portion 42, is disposed between the support plate 1 and the cover 6. In other words, the extension end 42E is disposed at a position separated from the cover 6 in the cover inner space 60 and does not penetrate the cover 6 in the normal direction.

In this embodiment, the extension portion 42 has a locking portion 420 that is locked to the molded resin 3. The locking portion 420 is disposed between the fixed side male thread portion 411 and the extension end portion 42E. Therefore, the locking portion 420 is disposed in the inner cover space 60 and embedded in the molded resin 3.

In this embodiment, the fixing member 4 is a bolt. In the illustrated example, the fixing member 4 is configured using a stud bolt having threaded portions at both ends. The above-mentioned fixed side male thread portion 411 is formed at one end of the fixing member 4, and the extension side male thread portion 421 is formed at the other end of the fixing member 4. In this example, the extension side male thread portion 421 constitutes the locking portion 420. The male thread 421a formed on the extension side male thread portion 421 generates friction with the molded resin 3, so that the extension side male thread portion 421 (locking portion 420) is locked to the molded resin 3.

The molded resin 3 is formed by drying and hardening an adhesive resin. The molded resin 3 is formed in the space 60 inside the cover. The first coil body 21, the second coil body 22, and the extension portion 42 of the fixing member 4 are embedded in the molded resin 3, and the molded resin 3 and the support plate 1 are integrally joined. The core 5 is also embedded in the molded resin 3. It is preferable that the molded resin 3 and the cover 6 are arranged so that they do not come into contact with each other. In other words, it is preferable that a small gap (for example, 1 mm to 2 mm) is formed between the molded resin 3 and the cover 6. This makes it possible to assemble the molded resin 3 and the cover 6 without interfering with each other, improving the ease of assembly of the coil unit 100.

As described above, the fixing portion 41 of the fixing member 4 is fixed to the support plate 1. In addition, since the extension portion 42 of the fixing member 4 is embedded in the molded resin 3, the molded resin 3 and the support plate 1 can be properly integrated. Therefore, the first coil body 21, the second coil body 22, and the core 5 embedded in the molded resin 3 can be properly integrated with the support plate 1. And, according to the coil unit 100 according to the present disclosure, since the fixing member 4 is arranged in the dead space (coil non-arrangement space Ga in the first direction X) between the curved portion (first curved portion 210) of the first coil body 21 and the curved portion (second curved portion 220) of the second coil body 22 in the first direction X, the molded resin 3 and the support plate 1 can be properly integrated while suppressing the expansion of the dimensions of the coil unit 100.

Next, a method for manufacturing the coil unit 100 described above, i.e., the coil unit 100 including the support plate 1, the coil 2, and the molded resin 3, will be described with reference mainly to Figs. 4 and 5. Fig. 4 is a flowchart showing the manufacturing process of the coil unit 100. Fig. 5 shows the coil unit 100 in the middle of its manufacturing process, and shows the state prior to the resin supplying process P6 in which resin is supplied to the inside of the mold 8 in which the coil 2, the core 5, and the fixing member 4 are arranged.

As shown in FIG. 4, the manufacturing method for the coil unit 100 according to this embodiment includes a support plate preparation process P1, a mold preparation process P2, a coil housing process P3, a core arrangement process P4, a fixing member arrangement process P5, a resin supply process P6, a mold removal process P7, and a cover attachment process P8. In this embodiment, each process is performed in the order shown in FIG. 4. In this embodiment, the coil arrangement process P9 includes the coil housing process P3 and the fixing member arrangement process P5.

The support plate preparation process P1 is a process for preparing the support plate 1. In this embodiment, the support plate preparation process P1 includes a process for attaching an insulating sheet 11 to a plate member 10 to form the support plate 1. The support plate preparation process P1 may also include a process for attaching a fixing member 4 to the support plate 1. In this case, the support plate preparation process P1 involves preparing the support plate 1 to which the fixing member 4 is attached.

The mold preparation process P2 is a process for preparing the mold 8 (see FIG. 5). The mold 8 has an internal space into which the resin is supplied and into which the molded resin 3 is formed. In this internal space, the coil 2, core 5, and fixing member 4 are placed by the coil accommodation process P3, the core placement process P4, and the fixing member placement process P5.

The coil arrangement process P9 is a process of arranging the coil 2 including the first coil body 21 and the second coil body 22 along the support surface F1 of the support plate 1. In the coil arrangement process P9, the first coil body 21 and the second coil body 22 are each formed into an annular shape when viewed in the normal direction along the normal direction of the support surface F1, and the first coil body 21 and the second coil body 22 are arranged so as to be adjacent to each other in the first direction X, which is a specific direction along the support surface F1 (see also FIG. 2). In the coil arrangement process P9, the coil 2 is arranged along the support surface F1 of the support plate 1 so as to form the curved portions (210, 220) in the portions of the first coil body 21 and the second coil body 22 that face each other in the first direction X and that are formed so as to move away from each other in the first direction X as they move outward in the second direction Y.

In this embodiment, the coil placement process P9 includes a coil accommodation process P3 and a fixing member arrangement process P5. The coil accommodation process P3 is a process of accommodating the coil 2 in the internal space of the mold 8. In this embodiment, in the coil accommodation process P3, the coil 2 is accommodated in the internal space of the mold 8 while the support plate 1 is separated from the mold 8. Then, in the fixing member arrangement process P5, which is performed after the coil accommodation process P3, the support plate 1 is arranged with respect to the mold 8 so that the coil 2 is along the support surface F1. In the coil accommodation process P3, after the fixing member arrangement process P5 is performed, the coil 2 is accommodated in the internal space of the mold 8 so that the first coil body 21 and the second coil body 22, which are each formed in an annular shape when viewed in the normal direction, are arranged adjacent to each other in the first direction X.

The core arrangement process P4 is a process of arranging the core 5. In the core arrangement process P4 according to this embodiment, the core 5 is continuously arranged in the first direction X so as to overlap with both the center position (first center position C1) of the first coil body 21 and the center position (second center position C2) of the second coil body 22 when viewed in the normal direction (see also FIG. 2). In addition, in the core arrangement process P4, the core 5 is arranged so that the core 5 has an overlapping portion 50 that overlaps with the coil 2 when viewed in the normal direction and a non-overlapping portion (51, 52) that does not overlap with the coil 2 when viewed in the normal direction.

The fixing member arrangement process P5 is a process of arranging the fixing member 4. In this embodiment, in the fixing member arrangement process P5, the fixing member 4 and the support plate 1 are arranged relative to the mold 8 so that the fixing member 4 is arranged as described below. The fixing member arrangement process P5 is performed at least before the resin supply process P6. In this embodiment, the fixing member arrangement process P5 is performed before the resin supply process P6 and after the coil accommodation process P3. In the fixing member arrangement process P5, the fixing member 4 is arranged between the curved portion (first curved portion 210) of the first coil body 21 and the curved portion (second curved portion 220) of the second coil body 22 in the first direction X, and the fixing portion 41 of the fixing member 4 is fixed to the support plate 1, and the extension portion 42 extending from the fixing portion 41 is arranged so as to extend toward the side where the first coil body 21 and the second coil body 22 are arranged with respect to the support surface F1. As described above, in the support plate preparation process P1, the support plate 1 to which the fixing member 4 is attached may be prepared. In this case, the process of "fixing the fixing portion 41 of the fixing member 4 to the support plate 1" in the fixing member placement process P5 is included in the support plate preparation process P1.

In the fixing member placement process P5 according to this embodiment, the fixing member 4 is placed so that the extension portion 42 (extending end portion 42E) of the fixing member 4 is positioned between the support plate 1 and the inner wall of the mold 8 (see FIG. 5). In other words, in the fixing member placement process P5, the fixing member 4 is placed so that the extending end portion 42E is positioned away from the inner wall of the mold 8.

By carrying out the coil accommodation process P3, core placement process P4, and fixing member placement process P5 described above, the coil 2, core 5, and fixing member 4 are placed in the internal space of the mold 8 as shown in FIG. 5.

The resin supplying process P6 is a process executed after the coil arrangement process P9 and the fixing member arrangement process P5. In this embodiment, since the fixing member arrangement process P5 is included in the coil arrangement process P9, "after the coil arrangement process P9 and the fixing member arrangement process P5" can be rephrased as "after the coil arrangement process P9". The resin supplying process P6 according to this embodiment is executed after the core arrangement process P4 in addition to the coil arrangement process P9 and the fixing member arrangement process P5. In the resin supplying process P6, resin is supplied to the area adjacent to the support surface F1 of the support plate 1 so that the first coil body 21, the second coil body 22, and the extension portion 42 of the fixing member 4 are embedded in the resin. In the resin supplying process P6 according to this embodiment, resin is supplied to the area adjacent to the support surface F1 of the support plate 1 so that the core 5 is also embedded in the resin. The resin supplying process P6 is executed by using a fluid adhesive resin as the resin and pouring the resin from the supply port 80 of the mold 8 into the internal space of the mold 8.

The mold removal process P7 is a process for removing the mold 8 from the support plate 1. In the mold removal process P7, the resin supplied to the internal space of the mold 8 hardens, and then the mold 8 is removed from the support plate 1.

The cover attachment process P8 is a process of attaching the cover 6 to the support plate 1. In the cover attachment process P8, the cover 6 is attached to the support plate 1 so as to cover the molded resin 3 in which the coil 2, the core 5, and the fixing member 4 are embedded.

In the manufacturing method of the coil unit 100, at least the fixing member arrangement process P5 is followed by the resin supply process P6. That is, by performing the fixing member arrangement process P5, the fixing member 4 is fixed to the support plate 1 by the fixing portion 41, and then, by performing the resin supply process P6, the extension portion 42 of the fixing member 4 is embedded in the resin, so that the molded resin 3 formed by the hardened resin can be properly integrated with the support plate 1. That is, as shown in FIG. 3, the resin is filled around the locking portion 420 formed in the extension portion 42, and the resin is deformed to match the shape of the locking portion 420 and hardened, so that the locking portion 420 is locked to the hardened molded resin 3. As a result, the fixing member 4 and the molded resin 3 are properly fixed. The fixing member 4 is also fixed to the support plate 1 by the fixing portion 41. Therefore, the support plate 1 and the molded resin 3 can be properly fixed via the fixing member 4.

Other embodiments
Next, other embodiments of the coil unit and the method for manufacturing the coil unit will be described.

(1) In the above embodiment, an example was described in which the fixing member 4 is configured using a stud bolt having threaded portions at both ends, and the extended side male threaded portion 421 formed at one end of the stud bolt constitutes the locking portion 420 that is engaged with the molded resin 3. However, without being limited to such an example, for example, as shown in FIG. 6, the fixing member may be configured using a bolt 4A having a head 420A, and the head 420A of the bolt 4A may constitute the locking portion 420. The head 420A of the bolt 4A becomes a hook and is engaged with the molded resin 3. Therefore, even with this configuration, the support plate 1 and the molded resin 3 can be appropriately fixed via the bolt 4A. In addition, as another example, as shown in FIG. 7, the fixing member may be configured using a rod-shaped member 4B having a bent portion 420B that is bent so as to intersect with the normal direction, and the bent portion 420B of the rod-shaped member 4B may constitute the locking portion 420. The bent portion 420B of the rod-shaped member 4B becomes a catch and is engaged with the molded resin 3. Therefore, even with this configuration, the support plate 1 and the molded resin 3 can be appropriately fixed via the rod-shaped member 4B.

(2) In the above embodiment, an example has been described in which the fixing member 4 is disposed between the curved portion (first curved portion 210) of the first coil body 21 and the curved portion (second curved portion 220) of the second coil body 22 in the first direction X. However, the fixing member 4 may be disposed in other locations in addition to between the first curved portion 210 and the second curved portion 220 in the first direction X. For example, in the cover inner space 60, when there is a dead space outside the first direction X with respect to the first coil body 21, the fixing member 4 may be disposed outside the first direction X with respect to the first coil body 21. In addition, in the cover inner space 60, when there is a dead space outside the first direction X with respect to the second coil body 22, the fixing member 4 may be disposed outside the first direction X with respect to the second coil body 22.

(3) In the above embodiment, an example was described in which the core placement process P4 is performed after the coil accommodation process P3, and the fixing member placement process P5 is performed after the core placement process P4. However, the present invention is not limited to this example, and the order in which the coil accommodation process P3, fixing member placement process P5, and core placement process P4 are performed can be determined arbitrarily. In addition, the coil accommodation process P3, fixing member placement process P5, and core placement process P4 may be performed simultaneously.

(4) In the above embodiment, an example was described in which the coil arrangement process P9 includes the coil housing process P3 and the fixing member arrangement process P5. However, without being limited to such an example, the coil arrangement process P9 may be configured not to include the fixing member arrangement process P5. For example, the coil 2 including the first coil body 21 and the second coil body 22 may be arranged along the support surface F1 of the support plate 1 by one process constituting the coil arrangement process P9. In this case, it is preferable to perform the core arrangement process P4 before the coil arrangement process P9 so that the core 5 can be easily arranged.

(5) In the above embodiment, an example was described in which the fixing member arrangement process P5 is performed after the coil accommodation process P3. In this fixing member arrangement process P5, the fixing member 4 is arranged between the curved portion (first curved portion 210) of the first coil body 21 and the curved portion (second curved portion 220) of the second coil body 22 in the first direction X, the fixing portion 41 of the fixing member 4 is fixed to the support plate 1, and the extension portion 42 extending from the fixing portion 41 is arranged so as to extend toward the side where the first coil body 21 and the second coil body 22 are arranged with respect to the support surface F1. However, without being limited to such an example, the fixing member arrangement process P5 may be performed before the coil accommodation process P3. In this case, the coil accommodation process P3 is performed after the fixing member arrangement process P5. Then, in this coil accommodation process P3, the coil 2 is arranged so that the fixing member 4 is sandwiched in the first direction X between the curved portion (first curved portion 210) of the first coil body 21 and the curved portion (second curved portion 220) of the second coil body 22. Even in this case, the fixing member 4 is ultimately arranged between the curved portion (first curved portion 210) of the first coil body 21 and the curved portion (second curved portion 220) of the second coil body 22 in the first direction X.

(6) In the above embodiment, an example was described in which the male thread 411a formed on the fixing portion 41 is screwed into the female thread 12a of the mounting hole 12 formed in the support plate 1 and fixed, thereby fixing the fixing member 4 to the support plate 1. However, without being limited to such an example, the fixing member 4 may be fixed to the support plate 1 by pressing the fixing portion 41 into the mounting hole 12. In this case, the male thread 411a may not be formed on the fixing portion 41, and the female thread 12a may not be formed in the mounting hole 12. Furthermore, as another example of pressing the fixing member 4 into the support plate 1, as shown in FIG. 8, a fixing member 4C formed of a press-in type stud bolt may be used, and the fixing member 4C may be pressed into the through hole 13 formed in the support plate 1 from the side opposite the support surface F1 of the support plate 1. At this time, it is preferable to press the fixing member 4C so that the head of the fixing member 4C does not protrude from the surface of the support plate 1 opposite the support surface F1. In the example shown in FIG. 8, the threaded portion 420C of the fixing member 4C constitutes the locking portion 420.

(7) In the above embodiment, an example has been described in which the first center position C1 of the first coil body 21 and the second center position C2 of the second coil body 22 in the normal direction view are disposed at the same position in the second direction Y, and the first outer edge portion 21E of the first coil body 21 and the second outer edge portion 22E of the second coil body 22 in the normal direction view are disposed at the same position in the second direction Y. However, without being limited to such an example, the first center position C1 of the first coil body 21 and the second center position C2 of the second coil body 22 may be disposed at positions shifted in the second direction Y. Also, the first outer edge portion 21E of the first coil body 21 and the second outer edge portion 22E of the second coil body 22 may be disposed at positions shifted in the second direction Y.

(8) In the above embodiment, an example was described in which the multiple fixing members 4 are arranged line-symmetrically with respect to the virtual line L connecting the first center position C1 and the second center position C2 when viewed in the normal direction. However, the multiple fixing members 4 do not have to be arranged line-symmetrically with respect to the virtual line L. In other words, the multiple fixing members 4 may be arranged at positions with different distances from the virtual line L in the second direction Y, or may be arranged at positions shifted from each other in the first direction X.

(9) In the above embodiment, an example has been described in which the core 5 is continuously arranged in the first direction X so as to overlap both the first central position C1 and the second central position C2 when viewed in the normal direction. However, without being limited to such an example, the core 5 may be formed using multiple magnetic bodies and may be arranged intermittently in the first direction X.

(10) In the above embodiment, an example has been described in which the coil unit 100 is used to charge an article transport vehicle V. Examples of objects to be charged using the coil unit 100 include various types of article transport vehicles V equipped with a power storage device 9v, and for example, a ceiling transport vehicle that travels along a travel path set near the ceiling may be the object.

(11) The configurations disclosed in the above-described embodiments may be combined with configurations disclosed in other embodiments, provided no contradictions arise. With respect to other configurations, the embodiments disclosed in this specification are merely examples in all respects. Therefore, various modifications may be made as appropriate within the scope of the spirit of this disclosure.

[Summary of the above embodiment]
The above-described coil unit and a method for manufacturing the coil unit will now be described.

A coil unit including a support plate, a coil disposed along a support surface of the support plate, and a mold resin,
The coil includes a first coil body and a second coil body that are each formed in an annular shape when viewed in a normal direction along the normal direction of the support surface, and that are arranged adjacent to each other in a first direction that is a specific direction along the support surface,
A direction perpendicular to the first direction when viewed in the normal direction is defined as a second direction,
each of the first coil body and the second coil body includes a curved portion formed in a portion facing each other in the first direction so as to move toward a side that moves away from each other in the first direction as the curved portion moves toward an outer side in the second direction;
a fixing member is disposed between the curved portion of the first coil body and the curved portion of the second coil body in the first direction;
the fixing member has a fixing portion fixed to the support plate and an extending portion arranged to extend from the fixing portion to a side where the first coil body and the second coil body are arranged with respect to the support surface,
The first coil body, the second coil body, and the extension portion are embedded in the molding resin, and the molding resin and the support plate are integrally joined together.

When a space forming member for forming a space in which a coil or molded resin is arranged is used as in the past, each member including the space forming member is joined to the molded resin, so that each member can be properly integrated. However, when forming a coil unit without using such a space forming member, it is necessary to properly integrate the molded resin and the member in contact with the molded resin. According to this configuration, the fixing portion of the fixing member is fixed to the support plate and the extension portion of the fixing member is embedded in the molded resin, so that the molded resin and the support plate can be properly integrated, and thus the first coil body and the second coil body embedded in the molded resin can be properly integrated with the support plate. Furthermore, according to this configuration, since the fixing member is disposed in the dead space between the curved portion of the first coil body and the curved portion of the second coil body in the first direction, the molded resin and the support plate can be properly integrated while suppressing the expansion of the dimensions of the coil unit. As described above, according to this configuration, each member constituting the coil unit can be properly integrated, and a coil unit that is easy to reduce costs can be realized.

Each of the first coil body and the second coil body is formed by winding an insulating coated linear conductor into a ring shape,
The support plate is made of metal,
The fixing member is a bolt,
It is preferable that a male thread formed on the fixing portion is screwed into a female thread formed on the support plate and fixed thereto.

According to this configuration, the first coil body and the second coil body are made of insulatingly coated linear conductors, so electrical insulation is easily ensured even when they are arranged along a metal support plate. This reduces the need to arrange separate insulating materials, etc., and makes it easier to reduce manufacturing costs and further the cost of the coil unit. In addition, because the male thread formed on the fixing part and the female thread formed on the support plate are screwed together, the fixing member can be easily and appropriately fixed to the support plate.

a center position of the first coil body and a center position of the second coil body when viewed in the normal direction are disposed at the same position in the second direction,
It is preferable that an outer edge portion of the first coil body and an outer edge portion of the second coil body when viewed in the normal direction are disposed at the same position in the second direction.

This configuration makes it easy to miniaturize the entire coil unit while maintaining the size of the first coil body and the second coil body.

A plurality of the fixing members are provided,
It is preferable that the multiple fixing members are arranged symmetrically with respect to an imaginary line connecting a central position of the first coil body and a central position of the second coil body when viewed in the normal direction.

This configuration makes it easier to make the position at which the molded resin is fixed to the support plate uniform with respect to the center positions of the first coil body and the second coil body. This makes it easier to ensure the fixing strength of the molded resin to the support plate.

a core made of a magnetic material is disposed between the first coil body, the second coil body and the support plate;
the core is continuously disposed in the first direction so as to overlap both a center position of the first coil body and a center position of the second coil body when viewed in the normal direction,
The core is preferably arranged in contact with the support surface.

This configuration makes it easier to release a large amount of magnetic flux on the side opposite the support plate. In addition, heat generated by the coil can be easily transferred to the support plate via the core, making it easier to improve the heat dissipation of the coil unit.

A method for manufacturing a coil unit including a support plate, a coil, and a molding resin, comprising the steps of:
a coil arrangement step of arranging the coil including a first coil body and a second coil body along a support surface of the support plate, a fixing member arrangement step of arranging a fixing member, and a resin supply step of supplying a resin, which is performed after the coil arrangement step and the fixing member arrangement step,
In the coil arrangement step, the first coil body and the second coil body are each formed into an annular shape when viewed in a normal direction along the normal direction of the support surface, and the first coil body and the second coil body are arranged so as to be adjacent to each other in a first direction, which is a specific direction along the support surface;
A direction perpendicular to the first direction when viewed in the normal direction is defined as a second direction,
a curved portion is a portion of each of the first coil body and the second coil body that faces each other in the first direction and is formed so as to move toward a side that moves away from each other in the first direction as it moves toward an outer side in the second direction,
In the fixing member arrangement step, the fixing member is arranged between the curved portion of the first coil body and the curved portion of the second coil body in the first direction, a fixing portion of the fixing member is fixed to the support plate, and an extension portion extending from the fixing portion is arranged so as to extend on a side where the first coil body and the second coil body are arranged with respect to the support surface;
In the resin supplying step, it is preferable that the resin is supplied to an area adjacent to the support surface of the support plate so that the first coil body, the second coil body, and the extension portion are embedded in the resin.

According to this configuration, the fixing member is fixed to the support plate by the fixing portion in the fixing member arrangement process, and then the extension portion of the fixing member is embedded in the resin in the resin supply process, so that the molded resin formed by the hardening of the resin can be properly integrated with the support plate. This allows the first coil body and the second coil body embedded in the molded resin to be properly integrated with the support plate. Furthermore, according to this configuration, the fixing member is arranged in the dead space between the curved portion of the first coil body and the curved portion of the second coil body in the first direction, so that the molded resin can be properly integrated with the support plate while suppressing the increase in the dimensions of the coil unit. As described above, according to this configuration, it is possible to properly integrate each member constituting the coil unit and realize a coil unit that is easy to reduce costs.

The technology disclosed herein can be used in a coil unit that includes a support plate, a coil arranged along the support surface of the support plate, and molded resin, and in a method for manufacturing the coil unit.

100: coil unit 1: support plate F1: support surface 12a: female thread 2 of support plate: coil 21: first coil body C1: center position 21E of first coil body: outer edge portion 210 of first coil body: curved portion 22 of first coil body: second coil body C2: center position 22E of second coil body: outer edge portion 220 of second coil body: curved portion 3 of second coil body: molded resin 4: fixing member 41: fixing portion 411a: male thread 42 of fixed side male thread portion: extension portion 421a: male thread 5 of extension side male thread portion: core L: imaginary line P3: coil arrangement process P5: fixing member arrangement process P6: resin supply process X: first direction Y: second direction

Claims (6)

A coil unit including a support plate, a coil disposed along a support surface of the support plate, and a mold resin,
The coil includes a first coil body and a second coil body that are each formed in an annular shape when viewed in a normal direction along the normal direction of the support surface, and that are arranged adjacent to each other in a first direction that is a specific direction along the support surface,
A direction perpendicular to the first direction when viewed in the normal direction is defined as a second direction,
each of the first coil body and the second coil body includes a curved portion formed in a portion facing each other in the first direction so as to move toward a side that moves away from each other in the first direction as the curved portion moves toward an outer side in the second direction;
a fixing member is disposed between the curved portion of the first coil body and the curved portion of the second coil body in the first direction;
the fixing member has a fixing portion fixed to the support plate and an extending portion arranged to extend from the fixing portion to a side where the first coil body and the second coil body are arranged with respect to the support surface,
the first coil body, the second coil body, and the extension portion are embedded in the molding resin, and the molding resin and the support plate are integrally joined. Each of the first coil body and the second coil body is formed by winding an insulating coated linear conductor into a ring shape,
The support plate is made of metal,
The fixing member is a bolt,
The coil unit according to claim 1 , wherein a male thread formed on the fixing portion is screwed into a female thread formed on the support plate and fixed thereto. a center position of the first coil body and a center position of the second coil body when viewed in the normal direction are disposed at the same position in the second direction,
The coil unit according to claim 1 , wherein an outer edge portion of the first coil body and an outer edge portion of the second coil body when viewed in the normal direction are disposed at the same position in the second direction. A plurality of the fixing members are provided,
The coil unit according to claim 1 , wherein the plurality of fixing members are arranged symmetrically with respect to a virtual line connecting a central position of the first coil body and a central position of the second coil body when viewed in the normal direction. a core made of a magnetic material is disposed between the first coil body, the second coil body and the support plate;
the core is continuously disposed in the first direction so as to overlap both a center position of the first coil body and a center position of the second coil body when viewed in the normal direction,
The coil unit according to claim 1 , wherein the core is disposed so as to be in contact with the support surface. A method for manufacturing a coil unit including a support plate, a coil, and a molding resin, comprising the steps of:
a coil arrangement step of arranging the coil including a first coil body and a second coil body along a support surface of the support plate, a fixing member arrangement step of arranging a fixing member, and a resin supply step of supplying a resin, which is performed after the coil arrangement step and the fixing member arrangement step,
In the coil arrangement step, the first coil body and the second coil body are each formed into an annular shape when viewed in a normal direction along the normal direction of the support surface, and the first coil body and the second coil body are arranged so as to be adjacent to each other in a first direction, which is a specific direction along the support surface;
A direction perpendicular to the first direction when viewed in the normal direction is defined as a second direction,
a curved portion is a portion of each of the first coil body and the second coil body that faces each other in the first direction and is formed so as to move toward a side that moves away from each other in the first direction as it moves toward an outer side in the second direction,
In the fixing member arrangement step, the fixing member is arranged between the curved portion of the first coil body and the curved portion of the second coil body in the first direction, a fixing portion of the fixing member is fixed to the support plate, and an extension portion extending from the fixing portion is arranged so as to extend on a side where the first coil body and the second coil body are arranged with respect to the support surface;
A method for manufacturing a coil unit, in which the resin supplying process supplies the resin to an area adjacent to the support surface of the support plate so that the first coil body, the second coil body, and the extension portion are embedded in the resin.

Images