Patent Application
20150145632
The present invention relates to a coil unit.
For the purpose of improving the transfer efficiency, the coil unit used in a wireless power supply system is composed of a magnetic body in order to increase the coupling coefficient between the coil unit for power transmission and the coil unit for power reception. When the magnetic body is composed by ceramic material, its mechanical stress is quite weak due to its hardness and fragility, and cracks would be produced once a certain impact is applied, and thus special attentions should be paid.
For such a requirement, Patent Document 1 has disclosed that the ferrite layer which is divided into ferrite sheets, the longest side of which is ten times or less as long as that of thickness, has been sufficiently divided so that it can be prevented from being further divided even a stress is applied when it is being mounted or after it is mounted.
Patent Document
Patent Document 1: JP-A-2011-211337
However, when the coil unit of the wireless power supply system in an electric vehicle or the like which needs high power transmission utilizes the technique disclosed in Patent Document 1, even if the ferrite layer is prepared into an individual piece to ensure the impact resistance, a new technical problem arises that the adjacent location between individual pieces may be locally heated.
In specific, the magnetic flux passing through the magnetic body has a property of congregating to a direct with a low magnetic resistance while there is a linear relationship between the magnetic flux density and the hysteresis loss or eddy current loss of the magnetic body, and thus the congregation of the magnetic flux i.e., the increase of the magnetic flux density has a tendency of involving local heating. However, in the ferrite layer as disclosed in Patent Document 1 which is divided into a plurality of ferrite sheets with irregular shapes, since the situation that the sharp corner portions between the adjacent individual pieces get close occurs, the magnetic flux is concentrated to the part with a low magnetic resistance i.e., the sharp corner portion of the individual piece, and thus a concern is present that the local intense heating may occur.
Therefore, the present invention is completed in view of the situation mentioned above, the aim of which is to provide a coil unit in which impact resistance is ensured and that has a magnetic body for heating prevention.
The coil unit according to the present invention that is a coil unit for wirelessly transmitting or receiving the power comprises a winding wire and a magnetic body, wherein in the magnetic body, a plurality of individual pieces with two principle surfaces opposing in a thickness direction are disposed in rows and columns in a direction substantially orthogonal to the thickness direction, and the two principle surfaces are in a polygonal shape, and interior angles forming a polygon are all obtuse angles (except for a right angle).
According to the present invention, since the magnetic body is composed of a plurality of individual pieces, a cracking of the magnetic body can be prevented even if a stress is applied, and thus an impact resistance can be ensured. In addition, since there are no sharp angles for interior angles in the two principle surfaces opposing in the thickness direction, a concentration of a magnetic flux can be inhibited at an adjacent location between individual pieces and a local heating at the adjacent location can be prevented.
The coil unit of the present invention that is a coil unit for wirelessly transmitting or receiving the power comprises a winding wire and a magnetic body, wherein in the magnetic body, a plurality of individual pieces with two principle surfaces opposing in a thickness direction are disposed in rows and columns in a direction substantially orthogonal to the thickness direction, and the two principle surfaces are in a substantially circular shape.
According to the present invention, since the magnetic body is composed of a plurality of individual pieces, a cracking of the magnetic body can be prevented even if a stress is applied and thus an impact resistance can be ensured. In addition, since there are no sharp angles for interior angles in the two principle surfaces opposing in the thickness direction, a concentration of a magnetic flux can be inhibited at an adjacent location between individual pieces and a local heating can be prevented at the adjacent location. In addition, since each individual piece is in a substantially circular shape, a powder of the magnetic body generated due to a friction caused by an impact at the adjacent location between individual pieces can be effectively prevented from dropping off.
Preferably, a plurality of individual pieces can be disposed in a zigzag pattern. In this case, since a number of the individual pieces per volume can be increased in the coil unit, an actual specific permeability of the coil unit can be increased, and further, a coupling efficiency between a power transmitting coil unit and a power receiving coil unit is improved.
Preferably, a plurality of individual pieces can be disposed in layers in the thickness direction, and the central parts of a plurality of individual pieces do not overlap each other when viewed from the thickness direction. In this case, an adjacent location between individual pieces disposed in rows and columns at one of the adjacent layers does not coincide with the adjacent location between individual pieces disposed in rows and columns at the other one of the adjacent layers in the thickness direction, and thus part of a magnetic flux leaked to outside the magnetic body will enter the individual piece in an adjacent layer during the magnetic flux passing through the adjacent location between individual pieces so that the magnetic flux will hardly leak to outside a power receiving coil unit. As a result, an actual magnetic permeability of the power receiving coil unit is increased, and further, a coupling efficiency between a power transmitting coil unit and the power receiving coil unit can be improved.
According to the present invention, a coil unit can be provided in which impact resistance is ensured and that has a magnetic body for heating prevention.
100 the power supply station
101 the power receiving coil unit
102 the power transmitting coil unit
200 the winding wire portion
201 the capacitor unit portion
203 the shield portion
202, 300, 400, 500, 600, 700, 800, 900 the magnetic body
701, 801, 901 a plurality of individual pieces forming the magnetic body
Hereinafter, the embodiments of the present invention will be described with reference to the drawings. In addition, the same reference numeral refers to the same element or an element having the same function, and repeated descriptions will be omitted in the description.
The wireless power supply system Si is provided at a power supply station 100 where vehicles can be parked in order to wirelessly transmit the power to the vehicles. The driver of a vehicle can manually or automatically park the vehicle at the power supply station 100 provided with the wireless power supply system S1, so that the power receiving coil unit 101 mounted in the vehicle is faced to the power transmitting coil unit 102.
From the view of shortening the charging time, i.e., the convenience, the power wirelessly transmitted is necessary at least 1.5 kW or more, and a power transmission of 3.3 kW or more is required.
At the power supply station 100, the power transmitting coil unit 102 or the like is provided on the ground surface below the vehicle or is embedded in the ground, and a power supply portion 103 and a commercial power line 104 are connected to the power transmitting coil unit 102.
The power supply portion 103 in the wireless power supply system S1 is composed of a converter portion 105 for converting an alternating current power with a commercial frequency from the input commercial power line 104 into a direct current power and a inverter portion 106 for transforming the direct voltage in the direct current power into an alternating square-wave voltage near the resonant frequency which will be described later. The inverter portion 106 is composed of, for example, four MOSFETs (Metal Oxide Semiconductor Field Effect Transistor) connected in full bridge.
The power transmitting coil unit 102 is mainly composed of a LC resonant circuit and is capable of transmitting the power output from the power transmitting coil unit 102 to the power receiving coil unit 101 by resonating with the oppositely disposed power receiving coil unit 101 which is mainly composed of the LC resonant circuit provided in the vehicle. In order to cause resonance between the power transmitting coil unit 102 and the power receiving coil unit 101, it is required that the resonant frequencies of the power receiving coil unit 102 and the power transmitting coil unit 101 get extremely close to each other. Thus, the inverter portion 106 can provide an alternating square-wave voltage near the resonant frequencies of the power transmitting coil unit 102 and the power receiving coil unit 101 to the power transmitting coil unit 102.
Next, the structure disposed at the vehicle side will be explained. The power receiving coil unit 101 is disposed on the bottom part of the vehicle.
As a result of the resonance with the power transmitting coil unit 102, the alternating current power received in the power receiving coil unit 101 is rectified in a rectification portion 107, and the rectified power is stored in a battery 109 via a DC/DC converter 108.
Then, the structure of the coil unit according to the preferable embodiments in the present invention will be described in detail. Further, the coil unit according to the preferable embodiments of the present invention is applicable to either of a power receiving coil unit and a power transmitting coil unit. In the following embodiment, an example applied to a power receiving coil unit in which impact resistance is particularly required will be described.
The power receiving coil unit 101 comprises a winding wire portion 200 formed by winding a metal wire, a capacitor unit portion 201 formed by connecting one or a plurality of capacitors in series or in parallel, a magnetic body 202 and a shield portion 203, and is configured by a case (not shown) formed of a resin or a nonmagnetic metal for accommodating them.
The metal wire used for the winding wire portion 200 is preferred to be the Litz wire. The Litz wire refers to a wire which is formed by intertwining a plurality of single bodies of copper, aluminum or the alloy thereof or by intertwining a plurality of filaments with a diameter of 0.2 mm or less obtained by stacking copper, aluminum or the alloy thereof. The number of turns in the winding wire portion 200 is properly adjusted for the purpose of adjusting the inductance of the power receiving coil unit 101. The value of the inductance can determine the resonant frequency by being matched with the value of the electrostatic capacity of the capacitor unit portion 201 to be described later. Therefore, in order to obtain the targeted resonant frequency, the inductance is adjusted via the number of turns of the winding wire portion 200. In the present embodiment, the winding wire portion 200 is formed by winding the Litz wire on an insulating plate 205 made of a resin. Thereby, the insulation between the Litz wire and the magnetic body 202 to be described later can be ensured. In addition, the winding wire portion 200 in the present embodiment is composed of a coil with a spiral structure formed by winding the Litz wire in a direction substantially orthogonal to the thickness direction into a plane.
The capacitor unit portion 201 is composed of a plurality of ceramic capacitors or film capacitors, and the total electrostatic capacity may determine the resonant frequency. Further, in the present embodiment, although one winding wire portion 200 and one capacitor unit portion 201 are connected in series, a plurality of capacitor unit portion 201 may be also connected to the winding wire portion 200 in series or in parallel in order to obtain the targeted resonant frequency. In addition, in the power receiving coil unit 101 of the present embodiment, although the capacitor portion 201 and the winding wire portion 200 are accommodated in a same case, a case for accommodating the capacitor unit portion 201 can be additionally provided, and the capacitor unit portion 201 and the rectification portion may also be integrated together. In other words, the capacitor unit portion 201 is not necessarily contained in the power receiving coil unit 101.
The shield portion 203 mainly functions to inhibit the change of the inductance value in the winding wire portion 200 due to the external effect. That is, the change of the inductance value in the power receiving coil unit 101 due to the effects from the main body of the vehicle, metal constructions present near the ground surface, constructions of a magnetic material or the like can be inhibited. The shield portion 203 is preferably positioned at a side opposite to the opposing power transmitting coil unit 102 with respect to the winding wire portion 200. In addition, the size of the shield portion 203 is preferably configured to cover the winding wire portion 200 when viewed from the thickness direction, and it is more preferable when the external size of the shield portion 203 viewed from the thickness direction is equal to or larger than that of the winding wire portion 200 viewed from the thickness direction, since the external effects can be further reduced. In addition, the thickness of the shield portion 203 in the thickness direction may be 1 mm or more. As such shield portion 203, nonmagnetic metal such as copper, aluminum or the like is preferably used.
It is expected that the magnetic body 202 is composed of the ceramics material with a large specific resistance, a large magnetic permittivity and a low hysteresis lag. For instance, the magnetic material such as ferrite is preferable and a ferrite sintered body containing manganese or zinc is more preferable. Such a magnetic body 202 is disposed at a side opposite to the opposing power transmitting coil unit with respect to the winding wire portion 200 and is parallel to the winding wire portion 200 in a direction orthogonal to the thickness direction. Specifically, the magnetic body 202 is positioned between the winding wire portion 200 and the shield portion 203. That is, in the thickness direction, the winding wire portion 200, the magnetic body 202 and the shield portion 203 are disposed in such sequence in a direction from the power transmitting coil unit 102 to the power receiving coil unit 101. Further, as described above, the magnetic body 202 is preferably electrically insulated from the winding wire portion 200 through the insulating plate 205. Also, the size of the magnetic body 202 is preferably configured to cover the winding wire portion 200 when viewed from the thickness direction, and it is more preferable when the external size of the magnetic body 202 viewed from the thickness direction is equal to or larger than that of the winding wire portion 200 viewed in the thickness direction, since the transmission efficiency between the power receiving coil unit 101 and the power transmitting coil unit 102 is improved.
In the present embodiment, the magnetic body 202 is composed of a plurality of individual pieces, and because it can be prevented from being further divided even if a stress is applied, the power receiving coil unit 101 with a high impact resistance is achieved.
Herein, referring to
As shown in
As described above, a plurality of individual pieces are disposed to be adjacent to each other in the row direction and the column direction, i.e., are disposed in rows and columns. At the time, the adjacent individual pieces among a plurality of individual pieces may also be disposed so as to abut each other. In addition, when the two principle surfaces of a plurality of individual pieces are composed of the regular hexagons as in the present embodiment, as shown in
As described above, in the power receiving coil unit 101 of the present embodiment, since the magnetic body 300 is composed of a plurality of individual pieces, the cracking of the magnetic body 300 can be prevented even if a stress is applied and thus the impact resistance can be ensured. Further, since there are no sharp angles in the interior angles of the two principle surfaces opposing in the thickness direction, the concentration of the magnetic flux at a location where the individual pieces are adjacent to each other can be inhibited and the local heating at the adjacent location can be prevented.
Similar to the power receiving coil unit 101 according to the first embodiment, the magnetic body 400 in the present embodiment is configured such that a plurality of individual pieces with two principle surfaces opposing in the thickness direction are disposed in rows and columns in a direction substantially orthogonal to the thickness direction. Herein, the thickness direction of the magnetic body 400 (hereinafter only referred to as “the thickness direction”) is set as the z-axis direction, the row direction of a plurality of individual pieces is set as the x-axis direction, and the column direction of a plurality of individual pieces is set as the y-axis direction which is orthogonal to both the x-axis and the z-axis in
As described above, a plurality of individual pieces are disposed to be adjacent in the row direction and the column direction, i.e., they are disposed in rows and columns. At the time, the adjacent individual pieces among a plurality of individual pieces may also be disposed to abut each other. In addition, when the two principle surfaces of a plurality of individual pieces are composed of perfect circles as in the present embodiment, a plurality of individual pieces are configured such that two individual pieces in the row direction are closest to a certain individual piece and two individual pieces in the column direction are closest to the certain individual piece as shown in
As described above, in the present embodiment, since the magnetic body 400 is composed of a plurality of individual pieces, the cracking of the magnetic body 400 can be prevented even if a stress is applied, and thus the impact resistance can be ensured. Further, since there are no sharp angles in the interior angles in the two principle surfaces opposing in the thickness direction, the concentration of the magnetic flux at a location where the individual pieces are adjacent to each other can be inhibited and the local heating at the adjacent location can be prevented. In addition, since each individual piece is in a substantially circular shape, the powder of the magnetic body generated due to the friction caused by the impact at the adjacent location between individual pieces can be effectively prevented from dropping off.
Similar to the magnetic body 400 according to the second embodiment, the magnetic body 500 of the present embodiment is configured such that a plurality of individual pieces with two principle surfaces opposing in the thickness direction are disposed in rows and columns in a direction substantially orthogonal to the thickness direction. Herein, the thickness direction of the magnetic body 500 (hereinafter only referred to as “the thickness direction”) is set as the z-axis direction, the row direction of a plurality of individual pieces is set as the x-axis direction, and the column direction of a plurality of individual pieces is set as the y-axis direction which is orthogonal to both the x-axis and the z-axis in
In the present embodiment, a plurality of individual pieces are disposed in a zigzag pattern as shown in
As described above, in the present embodiment, a plurality of individual pieces forming the magnetic body 500 are disposed in a zigzag pattern. Therefore, the number of individual pieces per volume can be effectively increased in the power receiving coil unit 101, and thus the actual specific permeability of the power receiving coil unit 101 is increased, and further, the coupling efficiency between the power transmitting coil unit 102 and the power receiving coil unit 101 can be improved.
In the present embodiment, a plurality of individual pieces forming the magnetic body 600 are disposed in layers in the thickness direction, and the central parts of a plurality of individual pieces are disposed not to overlap each other when viewed from the thickness direction as shown in
As described above, in the present embodiment, a plurality of individual pieces forming the magnetic body 600 are disposed in layers in the thickness direction, and the central parts of a plurality of individual pieces do not overlap each other when viewed from the thickness direction. Therefore, the adjacent location between individual pieces disposed in rows and columns at one of the adjacent layers does not coincide with the adjacent location between individual pieces disposed in rows and columns at the other one of the adjacent layers in the thickness direction, and thus part of the magnetic flux leaked to outside the magnetic body will enter the individual piece in an adjacent layer during the magnetic flux passing through the adjacent location between individual pieces so that the magnetic flux will hardly leak to outside the power receiving coil unit 101. As a result, the actual magnetic permeability of the power receiving coil unit 101 is increased, and further, the coupling efficiency between the power transmitting coil unit 102 and the power receiving coil unit 101 can be improved.
Hereinafter, the present invention will be more specifically explained by examples, but the present invention is not limited to these examples.
The power receiving coil unit in Example 1 was formed as follows. A Litz wire of copper obtained by intertwining 4000 bare wires with a diameter of 0.05 mm was used to the winding wire portion. The winding wire portion became almost square with an external size of 250 mm by winding the Litz wire for 23 turns, and the inductance value of the power receiving coil unit was set to be 100 uH. In addition, a plurality of ceramic capacitors were used to the capacitor unit portion, and a total electrostatic capacity of 25 nF is obtained. Then, the capacitor unit portion and the winding wire portion were connected in series, and as a result of that, a resonant frequency of 100 kHz is obtained. Further, aluminum with a thickness of 2 mm and an external size of 280 mm was used to the shield portion.
Next, a plurality of individual pieces of the magnetic body were formed as follows.
With respect to the winding wire portion, these winding wire portion, magnetic body 700 and the shield portion are configured such that an insulating plate of polycarbonate with a thickness of 3 mm was disposed on a surface of the power transmitting coil unit opposite to the winding wire portion, the aggregation of a plurality of individual pieces 701 which form the magnetic body 700 was disposed, and the shield portion was further disposed.
The power receiving coil unit of Example 1 with such a configuration was used to perform the wireless power transmission in a state where an electric load device (produced by Kikusui Electronics Corporation; product code: PLZ1004WH) was connected downstream the rectification portion. The load setting of the electronic load was adjusted so that the transmitted power had a direct current of 13 Arms and a power of 3.3 kW after rectified by the rectification portion. In order to investigate the local heating at the location where a plurality of individual pieces forming the magnetic body adjoined in the transmission test with a power of 3.3 kW, a thermal camera (produced by NEC Avio Infrared Technology; product code: F20W) and a thermoelectric couple (produced by Yokogawa Electric Corporation; product code: DU-100) were used to measure the thermal distribution at each location where a plurality of individual pieces forming the magnetic body adjoined along the measurement line 702 shown in
The power receiving coil unit of Example 2 was formed as follows.
As in Example 1, the power receiving coil unit of Example 2 with such a configuration was used to investigate the local heating at the location where a plurality of individual pieces 801 forming the magnetic body 800 adjoined in the transmission test with a power of 3.3 kW. A thermal camera (produced by NEC Avio Infrared Technology; product code: F20W) and a thermoelectric couple (produced by Yokogawa Electric Corporation; product code: DU-100) were used to measure the thermal distribution at each location where a plurality of individual pieces 801 forming the magnetic body 800 adjoined along the measurement line 802 shown in
The power receiving coil unit of Comparative Example 1 was formed as follows.
As in Example 1, the power receiving coil unit of Comparative Example 1 with such a configuration was used to investigate the local heating at the location where a plurality of individual pieces 901 forming the magnetic body 900 adjoined in the transmission test with a power of 3.3 kW. A thermal imaging camera (produced by NEC Avio Infrared Technology; product code: F20W) and a thermoelectric couple (produced by Yokogawa Electric Corporation; product code: DU-100) were used to measure the thermal distribution at each location where a plurality of individual pieces 901 forming the magnetic body 900 adjoined along the measurement line 902 shown in
The measuring results from Example 1, Example 2 and Comparative Example 1 were shown in
The present invention has been described based on the embodiments. These embodiments are exemplary, and various modifications and variations are possible within the scope defined by the claims of the present invention. Those skilled in the art will understand these modified examples and variations fall within the scope defined by the claims of the present invention. Thus, the description and the drawings are not limiting and should be deemed as exemplary.
For example, it goes without saying that even if the two principle surfaces of a plurality of individual pieces in the magnetic body are configured such that the structure in which a polygonal shape is present and all the interior angles forming the polygon are obtuse angles (except for the right angle) as shown in the first embodiment and the structure in which a substantially circular shape is present as shown in the second embodiment coexist, the effect of the present invention can also be obtained.
The coil unit of the present invention can be used in the coil unit of a wireless power supply system for charging a vehicle such as a battery electric vehicle or a plug-in hybrid electric vehicle.
| Number | Date | Country | Kind |
|---|---|---|---|
| 2013-246454 | Nov 2013 | JP | national |
| 2014-210938 | Oct 2014 | JP | national |
