Coil component, method for manufacturing coil component, power transmission device, power reception device, power transmission system, and moving object

Abstract

A coil component (10) is provided with: a first planar coil (11) that includes a plurality of turns (11n) and a protruding piece (11T) that extends from the inner peripheral edge and / or the outer peripheral edge of at least one of the plurality of turns (11n) and is bent so as to be separated from the turns (11n); and a first holding member (20) that overlaps the first planar coil (11) in a state in which the first holding member (20) is in contact with the plurality of turn portions (11n) of the first planar coil (11). Furthermore, the first holding member (20) includes a groove (22) on a first surface (20A) that overlaps the first planar coil (11), and the protruding piece (11T) is in contact with an inner surface of the groove (22) in a radial direction.

Description

Technical Field

[0001] The present disclosure relates to a coil component and a method for manufacturing the same, a power transmitting device, a power receiving device, a power transmission system, and a moving object. Background Art

[0002] Wireless power transmission systems that transmit power without contact are becoming popular.

[0003] For example, there is known a system that transmits electric power in a contactless manner by passing a high-frequency current through a resonant circuit including a coil.

[0004] When a high-frequency current flows through a coil, a skin effect may occur. The skin effect increases AC resistance, thereby causing a decrease in the transmission efficiency during power transmission. Considering this, when a coil is formed using a twisted wire, the skin effect can be suppressed to suppress the decrease in transmission efficiency. However, a twisted wire is formed by twisting a plurality of enameled wires, so the manufacturing cost is high and the manufacturing process takes time. The larger the size of the coil, the more time it takes to manufacture.

[0005] On the other hand, a technology is also known that uses a planar coil with a spiral shape and a plate shape, and a rectangular conductor cross section (see JP2015-518271A, JP2020-47614A, and JP2021-27112A). Such a planar coil can be formed, for example, by punching out a sheet material. Therefore, according to such a planar coil, regardless of the size of the coil, the manufacturing efficiency is improved. In addition, it is also advantageous in terms of thinning and lightening the device in which the coil is installed.

[0006] In addition, this planar coil is suitable for high-power wireless power transmission systems such as electric vehicles, where the coil size may become larger. In the wireless power transmission system for electric vehicles, the power transmission device is set on the road surface such as a parking lot, and the power receiving device is set on the electric vehicle. For example, when the above-mentioned planar coil is used in the use of electric vehicles, the height dimensions of the power transmission device and the power receiving device can be suppressed. Therefore, the above-mentioned planar coil plays a beneficial role in the field of vehicles, such as those requiring strict space constraints.

[0007] The above-mentioned planar coil may be integrated with the sheet material in a state of being overlapped with the sheet material containing resin, for example. Thereby, for example, the planar coil can be easily handled during assembly.

[0008] When the planar coil and the sheet are integrated, the planar coil may be embedded in the sheet with one side exposed. In this case, for example, the planar coil may be embedded in the sheet by pressing the planar coil against the sheet while heating the sheet. However, in this case, the planar coil may sometimes float away from the sheet. This floating may be caused by, for example, the difficulty in ensuring a firm adhesion at the interface due to different types of materials, and the difference in thermal expansion coefficient between the planar coil and the sheet.

[0009] As described above, if the planar coil floats from the sheet, for example, other parts cannot be properly loaded. In addition, if the positions of the planar coil and the sheet are deviated due to the floating, they cannot be properly loaded either.

[0010] The technical problem of the first and second disclosures is to provide a coil component and a manufacturing method thereof, a power transmitting device, a power receiving device, a power transfer system, and a movable body that can suppress the floating and deviation of a planar coil from a component integrated with the planar coil.

[0011] In addition, the coil is generally used in a state of being accommodated in a hollow housing. The coil is held in the housing by a holding member that is separate from the housing.

[0012] However, research is being conducted to form the housing and the coil as one piece so that the housing holds the coil. In other words, research is being conducted to form the housing as a holding component for holding the coil. In this case, the inner surface of the holding component has a shape corresponding to the shape of the coil and other parts attached to the coil. For example, in the case where the coil is formed into a spiral shape, as shown in JP2021-27112A, a magnetic body is arranged between adjacent parts of the coil. Therefore, a groove is formed on the inner surface of the holding component to accommodate the front end of the magnetic body.

[0013] Such a retaining member can be made of a thermoplastic material or a thermosetting material. Specifically, the retaining member can be made by inserting a heated and molten material into a mold having a concave-convex shape corresponding to the concave-convex shape of the inner surface of the retaining member and then cooling the mold. However, the retaining member made in this way may sometimes be warped.

[0014] The third disclosed technical problem is to provide a coil component capable of reducing warping of a holding member that holds a coil, a method for manufacturing the same, a power transmitting device, a power receiving device, a power transfer system, and a moving object.

[0015] In addition, in the above-mentioned wireless power transmission system, it is desired to improve the performance of the coil component and perform efficient power transmission. JP2023-88728A studies improving the performance of the coil component by providing a magnetic wall between adjacent turns of the coil.

[0016] As described above, when the housing is formed as a holding member for holding the coil, the inner surface of the holding member has a shape corresponding to the shape of the coil and other parts attached to the coil. Therefore, when the wall of the magnetic body extends from the coil, it is necessary to form a groove on the inner surface of the holding member to accommodate the wall.

[0017] In order to improve the performance of the coil part, it is desirable to increase the height of the magnetic body wall. In this case, it is necessary to deepen the groove of the holding component. However, if the groove of the holding component is deepened, the thickness of the portion of the holding component that forms the groove becomes thinner, and there is a concern that the strength of the holding component (and therefore the strength of the coil part) will be reduced. In addition, if the groove of the holding component becomes deeper, it becomes difficult to form the holding component, and therefore, there is a concern that the manufacture of the coil part will become difficult.

[0018] The fourth disclosed technical problem is to provide a coil part and a manufacturing method thereof, a power transmitting device, a power receiving device, a power transmission system, and a movable body, which can suppress the possibility of a decrease in the strength of the coil part due to the formation of a magnetic wall and can easily manufacture a coil part having a magnetic wall. Summary of the invention

[0019] <First Public Release>

[0020] The technical problem of the first disclosure is to provide a coil component and a manufacturing method thereof, a power transmitting device, a power receiving device, and a power transmission system that can suppress the floating and deviation of a planar coil from a component integrated with the planar coil.

[0021] The first disclosure provides a coil component comprising:

[0022] A first planar coil including a plurality of turns arranged in a radial direction and a protruding piece extending from an inner periphery and / or an outer periphery of at least one of the plurality of turns and bent away from the turn; and

[0023] a first holding member overlapping the first planar coil in a state of being in contact with the plurality of turn portions,

[0024] The first holding member includes a groove on a surface overlapping the first planar coil,

[0025] The protruding piece is in contact with the inner surface of the groove in the radial direction.

[0026] In the first disclosed coil component,

[0027] The turn portion may also be located outside the groove.

[0028] In the first disclosed coil component,

[0029] The device may further include a second holding member having magnetism and being integrated with the first planar coil and the first holding member so as to sandwich the first planar coil with the first holding member.

[0030] The groove may also be filled with a portion of the second retaining member.

[0031] In the first disclosed coil component,

[0032] A second planar coil may be embedded in the second holding member, the second planar coil being located at a position overlapping the first planar coil.

[0033] The second planar coil may also include a plurality of turns arranged in a radial direction, and a protruding piece extending from an inner periphery and / or an outer periphery of at least one of the plurality of turns and bent away from the turn of the second planar coil.

[0034] The protruding piece of the second planar coil may be in contact with the second holding member in the radial direction.

[0035] In the first disclosed coil component,

[0036] The first holding member may further include a protrusion that protrudes from the groove and is embedded in the second holding member.

[0037] The protrusion may face the protruding piece of the second planar coil in the radial direction.

[0038] In the first disclosed coil component,

[0039] Alternatively, the first retaining member may further include a spacer portion at least in any one of a portion between the groove on the surface overlapping the first planar coil and the turn portion inward in the radial direction relative to the groove and a portion between the groove and the turn portion outward in the radial direction relative to the groove, wherein the spacer portion protrudes away from the first planar coil and is adjacent to the protrusion in the radial direction.

[0040] In the coil component of the first disclosure, the groove may extend in a spiral shape along the plurality of turns.

[0041] In the first disclosed coil component,

[0042] The groove may also include a recess,

[0043] At least a portion of the protruding piece (of the first planar coil) may be located in the recessed portion.

[0044] In the coil component of the first disclosure, the protruding piece may extend from the inner peripheral edge and the outer peripheral edge of the turn portion.

[0045] In the coil component of the first disclosure, the protruding piece may extend only from the outer peripheral edge of the turn portion.

[0046] In the coil component disclosed in the first disclosure, the turn portion connected to the protruding piece may include a through hole at a position adjacent to the protruding piece in the radial direction.

[0047] The first disclosure provides a method for manufacturing a coil component, comprising:

[0048] A step of preparing a coil intermediate material including a plurality of turn portions arranged in a radial direction and a connecting portion connecting the turn portions adjacent to each other in the radial direction;

[0049] A step of preparing a mold having a convex portion formed thereon;

[0050] A step of placing the coil intermediate material in the mold so that the connecting portion faces the convex portion and the adjacent turn portions connected by the connecting portion face a portion of the mold different from the convex portion;

[0051] A step of pushing a forming material into the die via the coil intermediate material, and relatively pressing the convex portion into the forming material via the connecting portion, thereby separating the connecting portion from any one of the adjacent turn portions, and bending the connecting portion away from the turn portion, and forming a groove in the forming material; and

[0052] A step of removing the molding material from the mold after solidifying the molding material.

[0053] In the first disclosed method for manufacturing a coil component,

[0054] The mold may also have a positioning protrusion rising from a portion different from the convex portion.

[0055] The turn portion connected to the connecting portion may also have a through hole at a position adjacent to the connecting portion in the radial direction.

[0056] The coil intermediate material is placed in the die in a state where the positioning protrusion passes through the through hole.

[0057] In the method for manufacturing a coil component according to the first disclosure, the connection portion may include a narrowed portion where a cross-sectional area is locally reduced.

[0058] In the method for manufacturing a coil component according to the first disclosure, the narrowed portion may be formed at an intermediate position of the connecting portion in the radial direction.

[0059] In the method for manufacturing a coil component according to the first disclosure, the narrowed portion may be formed at an outer end portion of the connecting portion in the radial direction.

[0060] The first disclosure provides a method for manufacturing a coil component, comprising:

[0061] A step of preparing a preliminary coil component, the preliminary coil component comprising a first planar coil including a plurality of turns arranged in a radial direction, and a first holding member overlapping the first planar coil in a state of being in contact with the plurality of turns, the first holding member including a groove on a surface overlapping the first planar coil, the groove being formed to be open between adjacent turns, and the first holding member further including a protrusion protruding from the groove;

[0062] a step of preparing a second coil intermediate material, the second coil intermediate material including a plurality of turns arranged in the radial direction and a connecting portion connecting the turns adjacent to each other in the radial direction;

[0063] a step of overlapping the second coil intermediate material and the first planar coil in such a manner that the connecting portion and the protruding portion face each other; and

[0064] A step of pressing the connection portion against the protrusion to separate the connection portion from any one of the adjacent turn portions connected to the connection portion and to bend the connection portion away from the turn portion.

[0065] The first disclosure provides a power transmission device including any one of the coil components according to the first disclosure.

[0066] The first disclosure provides a power receiving device including any one of the coil components according to the first disclosure.

[0067] A first disclosure provides a power transmission system,

[0068] It has a power transmission device and a power receiving device.

[0069] At least one of the power transmitting device and the power receiving device includes any one of the coil components disclosed in the first disclosure.

[0070] The first disclosure provides a movable body including any one of the coil components according to the first disclosure.

[0071] According to the first disclosure, it is possible to suppress the planar coil from floating or deviating from the member integrated with the planar coil.

[0072] <Second Publication>

[0073] The second disclosed technical problem is to provide a coil component capable of suppressing the floating of a planar coil from a sheet integrated with the planar coil, a method for manufacturing the same, a coil intermediate material, a power transmitting device, a power receiving device, a power transmission system, and a movable body.

[0074] The second disclosure provides a coil component,

[0075] It comprises: a planar coil having a spiral shape, comprising a first surface and a second surface opposite to each other in the axial direction and extending on the central axis of the spiral shape; and a first holding component, which overlaps with the planar coil in a manner opposite to the second surface and holds the planar coil, and a through hole is formed on the planar coil that passes from the first surface to the second surface, and the first holding component comprises: a base portion, which comprises a contact surface that is connected to the second surface and extends along the second surface; and a rib portion, which protrudes from the contact surface and passes through the through hole, and is in contact with or close to the inner circumferential surface of the through hole in the radial direction of the planar coil orthogonal to the central axis.

[0076] In the second disclosed coil component,

[0077] The first retaining member may also include a plurality of ribs.

[0078] A plurality of the ribs may be arranged side by side at intervals in the radial direction.

[0079] In the second disclosed coil component,

[0080] The rib may also include: a raised portion that contacts or approaches the through hole in the radial direction and passes over the planar coil in the axial direction; and an overhang portion that extends from the raised portion in the radial direction and is opposite to the first surface.

[0081] The second disclosure provides a coil component comprising:

[0082] A planar coil having a spiral shape, comprising a first surface and a second surface extending on a central axis of the spiral shape and opposite to each other in the axial direction; and

[0083] a first holding member which overlaps the planar coil so as to face the second surface and holds the planar coil;

[0084] The first holding member includes: a base portion including a contact surface that is in contact with the second surface and extends along the second surface; and a rib portion that protrudes from the contact surface and contacts or approaches a side surface of the planar coil located between the first surface and the second surface in a radial direction of the planar coil orthogonal to the central axis.

[0085] The rib includes: a raised portion that contacts or approaches the side surface of the planar coil in the radial direction and passes over the planar coil in the axial direction; and an overhang portion that extends from the raised portion in the radial direction and is opposite to the first surface.

[0086] In the second disclosed coil component,

[0087] The raised portion may also extend in a spiral shape along the spiral-shaped planar coil.

[0088] In the second disclosed coil component,

[0089] The raised portion may also include: an inner raised portion that contacts or approaches an inner peripheral side surface of the side surface facing the central axis in the radial direction; and an outer raised portion that contacts or approaches an outer peripheral side surface located on the side surface opposite to the inner peripheral side surface.

[0090] The inner raised portion and the outer raised portion may protrude from the contact surface in a state of being separated in the radial direction.

[0091] In the second disclosed coil component,

[0092] The rib may also include a plurality of overhanging portions,

[0093] The plurality of overhanging portions may be provided at intervals in a direction in which the planar coil extends in a spiral shape.

[0094] In the second disclosed coil component,

[0095] A plurality of the overhanging portions may also be arranged side by side at intervals in the radial direction or in a direction parallel to the radial direction.

[0096] In the second disclosed coil component,

[0097] The overhanging portion may also partially cover the first surface.

[0098] In the second disclosed coil component,

[0099] The overhanging portion may also cover a range less than 25% of the area of ​​the first surface.

[0100] In the second disclosed coil component,

[0101] The first holding member may be non-magnetic and insulating.

[0102] In the second disclosed coil component,

[0103] A second holding member may be further provided. The second holding member has magnetism and is integrated with the planar coil and the first holding member so as to sandwich the planar coil with the first holding member.

[0104] In the second disclosed coil component,

[0105] The planar coil may also include a plurality of turns arranged along the radial direction.

[0106] The first holding member may also form a groove in a portion of the contact surface located between adjacent turns.

[0107] The second holding member may be filled in the groove.

[0108] In the second disclosed coil component,

[0109] A first magnetic shielding member may be further provided, the first magnetic shielding member being arranged to face the first surface of the planar coil.

[0110] The first magnetic shielding member may include a plurality of magnetic plates having magnetism.

[0111] The plurality of magnetic plates may include two magnetic plates, and the two magnetic plates are arranged to sandwich the plurality of overhanging portions that are arranged side by side at intervals in the radial direction.

[0112] In the second disclosed coil component,

[0113] An adhesive layer containing a thermoplastic resin for bonding the second surface and the contact surface may be further provided.

[0114] In the second disclosed coil component,

[0115] The surface roughness of the second surface may also be greater than the surface roughness of the first surface.

[0116] The second disclosure provides a method for manufacturing a coil component, comprising:

[0117] A step of preparing a mold having a concave portion formed therein;

[0118] A step of preparing a planar coil having a spiral shape and including a first surface and a second surface extending on a central axis of the spiral shape and opposite to each other in an axial direction;

[0119] A step of placing the planar coil in the mold in a state where the first surface faces the surface of the mold on which the recess is formed and the planar coil partially covers the recess; and

[0120] A step of providing a molding material in a manner covering the second surface, forming a portion filling the recess and a portion covering the second surface with the molding material, and solidifying the molding material in a state where the portion filling the recess and the portion covering the second surface are connected.

[0121] In the second disclosed method for manufacturing a coil component,

[0122] A through hole penetrating from the first surface to the second surface may be formed on the planar coil.

[0123] The planar coil may be placed in the mold in a state where the through hole and the recessed portion overlap, and the molding material may be filled from the through hole into the recessed portion.

[0124] In the second disclosed method for manufacturing a coil component,

[0125] The planar coil may also be placed in the mold in a state where it partially covers the recessed portion.

[0126] The molding material may be filled into the recess from a portion of the recess that is not covered by the planar coil.

[0127] In the second disclosed method for manufacturing a coil component,

[0128] A support portion may also be provided in the mold, wherein the support portion is formed to be located inside the recessed portion.

[0129] The planar coil may be placed in the mold such that a portion of the planar coil covering the recessed portion overlaps the supporting portion.

[0130] The second disclosure provides a method for manufacturing a coil component, comprising:

[0131] The process of preparing the mold;

[0132] A step of preparing a planar coil having a spiral shape, including a first surface and a second surface extending on a central axis of the spiral shape and opposite to each other in the axial direction, and having a through hole penetrating from the first surface to the second surface;

[0133] a step of placing the planar coil in the mold; and

[0134] The step of providing a molding material so as to cover the second surface, forming a portion filling the through hole and a portion covering the second surface with the molding material, and solidifying the molding material in a state where the portion filling the through hole and the portion covering the second surface are connected.

[0135] The second disclosure provides a coil intermediate material, which comprises:

[0136] A planar coil having a spiral shape, comprising a first surface and a second surface extending on a central axis of the spiral shape and opposite to each other in the axial direction; and

[0137] a first holding member which overlaps the planar coil so as to face the second surface and holds the planar coil;

[0138] A through hole is formed on the planar coil, penetrating from the first surface to the second surface.

[0139] The first retaining component includes: a base portion, which includes a contact surface connected to the second surface and extending along the second surface; and a rib portion, which protrudes from the contact surface and passes through the through hole, and is in contact with or close to the inner circumferential surface of the through hole in a radial direction of the planar coil orthogonal to the center axis.

[0140] The second disclosure provides a coil intermediate material, which comprises:

[0141] A planar coil having a spiral shape, comprising a first surface and a second surface extending on a central axis of the spiral shape and opposite to each other in the axial direction; and

[0142] a first holding member which overlaps the planar coil so as to face the second surface and holds the planar coil;

[0143] The first holding member includes: a base portion including a contact surface that is in contact with the second surface and extends along the second surface; and a rib portion that protrudes from the contact surface and contacts or approaches a side surface of the planar coil located between the first surface and the second surface in a radial direction of the planar coil orthogonal to the central axis.

[0144] The rib includes: a raised portion that contacts or approaches the side surface of the planar coil in the radial direction and passes over the planar coil in the axial direction; and an overhang portion that extends from the raised portion in the radial direction and is opposite to the first surface.

[0145] The second disclosure provides a power transmission device including any one of the coil components according to the second disclosure.

[0146] The second disclosure provides a power receiving device including any one of the coil components of the second disclosure.

[0147] A second disclosure provides a power transmission system,

[0148] Equipped with a power transmission device and a power receiving device,

[0149] At least one of the power transmitting device and the power receiving device includes any one of the coil components disclosed in the second disclosure.

[0150] The second disclosure provides a moving object including any one of the coil components according to the second disclosure.

[0151] According to the second disclosure, it is possible to suppress the planar coil from floating from the sheet integrated with the planar coil.

[0152] <Third Publication>

[0153] The third disclosed technical problem is to provide a coil component capable of reducing warping of a holding member that holds a coil, a method for manufacturing the same, a power transmitting device, a power receiving device, a power transfer system, and a moving object.

[0154] A third disclosure provides a coil component comprising:

[0155] A planar coil having a spiral shape, comprising a first surface and a second surface extending on a central axis of the spiral shape and opposite to each other in the axial direction;

[0156] a first holding member overlapping the planar coil so as to face the second surface and holding the planar coil; and

[0157] a second holding member which is integrated with the planar coil and the first holding member in such a manner as to sandwich the planar coil with the first holding member;

[0158] The planar coil includes a plurality of turns arranged along a radial direction of the planar coil.

[0159] The second holding member has a protrusion extending along the axial direction between adjacent turns of the planar coil.

[0160] The first holding member has a contact surface that contacts the second surface and an outer surface on a side opposite to the contact surface.

[0161] A first groove for accommodating the protrusion is formed on the contact surface,

[0162] A second groove is formed on the outer surface,

[0163] The second groove is formed in a region of the outer surface overlapping with a region on the contact surface including the center axis and the first groove when viewed in the axial direction.

[0164] In the third disclosed coil component,

[0165] The second groove may also be formed along the spiral shape of the planar coil when viewed in the axial direction.

[0166] In the third disclosed coil component,

[0167] The width of the second groove may also be 0.2 to 1.1 times the width of the first groove.

[0168] In the third disclosed coil component,

[0169] The depth of the second groove may be 0.2 to 1.1 times the depth of the first groove.

[0170] In the third disclosed coil component,

[0171] The volume of the second groove may also be 0.2 to 1.1 times the volume of the first groove.

[0172] In the third disclosed coil component,

[0173] When viewed in the axial direction, the second groove may not overlap with the first groove.

[0174] A third disclosure provides a coil component comprising:

[0175] A planar coil having a spiral shape, comprising a first surface and a second surface extending on a central axis of the spiral shape and opposite to each other in the axial direction;

[0176] a first holding member overlapping the planar coil so as to face the second surface and holding the planar coil; and

[0177] a second holding member which is integrated with the planar coil and the first holding member in such a manner as to sandwich the planar coil with the first holding member;

[0178] The planar coil includes a plurality of turns arranged along a radial direction of the planar coil.

[0179] The second holding member has a protrusion extending along the axial direction between adjacent turns of the planar coil.

[0180] The first holding member has a contact surface that contacts the second surface and an outer surface on a side opposite to the contact surface.

[0181] A first groove for accommodating the protrusion is formed on the contact surface,

[0182] At least one rib is formed on the outer surface,

[0183] The at least one rib is formed on a region of the outer surface overlapping with a region on the contact surface including the central axis and the first groove when viewed in the axial direction.

[0184] In the third disclosed coil component,

[0185] The at least one rib may also include a plurality of ribs extending in directions intersecting each other.

[0186] In the third disclosed coil component,

[0187] The at least one rib may include a plurality of ribs, and the plurality of ribs may be formed in a lattice shape when viewed in the axial direction.

[0188] In the third disclosed coil component,

[0189] The first holding member may be non-magnetic and insulating.

[0190] In the third disclosed coil component,

[0191] The second holding member may also be magnetic.

[0192] In the third disclosed coil component,

[0193] The planar coil may also be formed in a plate shape.

[0194] In the third disclosed coil component,

[0195] The planar coil may also be formed using litz wires.

[0196] The third disclosure provides a coil intermediate material, which comprises:

[0197] A planar coil having a spiral shape, comprising a first surface and a second surface extending on a central axis of the spiral shape and opposite to each other in the axial direction; and

[0198] a first holding member which overlaps the planar coil so as to face the second surface and holds the planar coil;

[0199] The planar coil includes a plurality of turns arranged along a radial direction of the planar coil.

[0200] The first holding member has a contact surface that contacts the second surface and an outer surface on a side opposite to the contact surface.

[0201] A first groove is formed on the contact surface,

[0202] A second groove is formed on the outer surface,

[0203] When viewed in the axial direction, the first groove is formed between adjacent turns of the planar coil along the spiral shape of the planar coil.

[0204] The second groove is formed in a region of the outer surface overlapping with a region on the contact surface including the center axis and the first groove when viewed in the axial direction.

[0205] In the third disclosed coil intermediate material,

[0206] The second groove may also be formed along the spiral shape of the planar coil when viewed in the axial direction.

[0207] The third disclosure provides a coil intermediate material, which comprises:

[0208] A planar coil having a spiral shape, comprising a first surface and a second surface extending on a central axis of the spiral shape and opposite to each other in the axial direction; and

[0209] a first holding member which overlaps the planar coil so as to face the second surface and holds the planar coil;

[0210] The planar coil includes a plurality of turns arranged along a radial direction of the planar coil.

[0211] The first holding member has a contact surface that contacts the second surface and an outer surface on a side opposite to the contact surface.

[0212] A first groove is formed on the contact surface,

[0213] At least one rib is formed on the outer surface,

[0214] When viewed in the axial direction, the first groove is formed between adjacent turns of the planar coil along the spiral shape of the planar coil.

[0215] The at least one rib is formed on a region of the outer surface overlapping with a region on the contact surface including the central axis and the first groove when viewed in the axial direction.

[0216] In the third disclosed coil intermediate material,

[0217] The at least one rib may also include a plurality of ribs extending in directions intersecting each other.

[0218] The third disclosure provides a power transmission device including any one of the coil components according to the third disclosure.

[0219] The third disclosure provides a power receiving device including any one of the coil components according to the third disclosure.

[0220] A third disclosure provides a power transmission system,

[0221] Equipped with a power transmission device and a power receiving device,

[0222] At least one of the power transmitting device and the power receiving device includes any one of the coil components according to the third disclosure.

[0223] The third disclosure provides a movable body including any one of the coil components according to the third disclosure.

[0224] According to the third disclosure, warping of the holding member that holds the coil can be reduced.

[0225] <Fourth Publication>

[0226] The fourth disclosed technical problem is to provide a coil part and its manufacturing method, a power transmitting device, a power receiving device, a power transmission system, and a movable body, which can suppress the possibility of reducing the strength of the coil part due to the formation of a magnetic wall and can also easily manufacture the coil part with a magnetic wall.

[0227] A fourth disclosure provides a coil component, comprising:

[0228] A planar coil having a spiral shape, comprising a first surface and a second surface opposite to the first surface;

[0229] a first holding member overlapping the planar coil so as to face the first surface and holding the planar coil; and

[0230] a second holding member, which clamps the planar coil together with the first holding member,

[0231] The planar coil comprises a plurality of turns arranged along the radial direction of the planar coil, that is, along the radial direction of the coil.

[0232] The first holding member has a contact surface that contacts the first surface.

[0233] A groove is formed on the contact surface, and when viewed in the axial direction of the planar coil, that is, in the axial direction of the coil, the groove extends between adjacent turns of the planar coil.

[0234] The second holding member includes a base portion contacting the second surface of the planar coil, and a wall portion extending from the base portion through between adjacent turns of the planar coil and into the groove of the first holding member.

[0235] The width of the bottom of the groove is narrower than the width of the groove at a height position of the contact surface.

[0236] In the fourth disclosed coil component,

[0237] The surface of the first holding member that defines the slot may include a pair of slot side surfaces that face each other in the radial direction of the coil.

[0238] At least one of the pair of slot side surfaces may include an inclined surface inclined with respect to the coil axial direction.

[0239] In the fourth disclosed coil component,

[0240] The slot side surface located on the outer side in the radial direction of the coil among the pair of slot side surfaces may have an inclined surface inclined with respect to the axial direction of the coil.

[0241] In the fourth disclosed coil component,

[0242] The slot side surface located on the inner side in the radial direction of the coil among the pair of slot side surfaces may have an inclined surface inclined with respect to the axial direction of the coil.

[0243] In the fourth disclosed coil component,

[0244] Each of the pair of slot sides may have an inclined surface inclined with respect to the coil axial direction.

[0245] In the fourth disclosed coil component,

[0246] The wall portion may also have a base end portion extending from the base portion along the coil axial direction with a uniform width.

[0247] A dimension of the base end portion along the axial direction of the coil may be larger than a thickness of the planar coil.

[0248] In the fourth disclosed coil component,

[0249] The distance between the top of the groove and the contact surface may be greater than 2 mm.

[0250] In the fourth disclosed coil component,

[0251] The width of the bottom of the groove may be less than or equal to one-half of the width of the groove at a height position of the contact surface.

[0252] In the fourth disclosed coil component,

[0253] The first retaining member may also comprise fibers.

[0254] In the fourth disclosed coil component,

[0255] The first holding member may be non-magnetic and insulating.

[0256] In the fourth disclosed coil component,

[0257] The second holding member may also be magnetic.

[0258] In the fourth disclosed coil component,

[0259] The planar coil may also be formed in a plate shape.

[0260] A fourth disclosure provides a power transmission device including any one of the coil components according to the fourth disclosure.

[0261] A fourth disclosure provides a power receiving device including any one of the coil components according to the fourth disclosure.

[0262] A fourth disclosure provides a power transmission system,

[0263] Equipped with a power transmission device and a power receiving device,

[0264] At least one of the power transmitting device and the power receiving device includes any one of the coil components according to the fourth disclosure.

[0265] A fourth disclosure provides a movable body including any one of the coil components according to the fourth disclosure.

[0266] A fourth disclosure provides a method for manufacturing a coil component, comprising:

[0267] a step of preparing a mold having a main body and a spiral-shaped protrusion extending from the main body;

[0268] a step of arranging a spiral-shaped planar coil corresponding to the spiral shape of the convex portion in the main body of the mold so that the convex portion protrudes from between adjacent turns of the planar coil;

[0269] A step of forming a first holding member by pressing a material for making a first holding member in a mold in which the planar coil is arranged, thereby making a coil intermediate material in which the first holding member and the planar coil are integrated;

[0270] a step of removing the mold from the coil intermediate material; and

[0271] After removing the mold from the coil intermediate material, a second holding body covering the planar coil is formed on the coil intermediate material.

[0272] The width of the top of the convex portion of the mold is narrower than the width of the convex portion at a connection position with the main body portion.

[0273] In the fourth disclosed method for manufacturing a coil component,

[0274] The convex portion may also have a pair of mold side surfaces facing each other in the radial direction of the convex portion, that is, in the radial direction of the mold,

[0275] At least one of the pair of mold side surfaces may have an inclined surface inclined with respect to the axial direction of the protrusion, that is, the mold axial direction.

[0276] In the fourth disclosed method for manufacturing a coil component,

[0277] The mold side surface located on the outer side in the mold radial direction of the pair of mold side surfaces may have an inclined surface inclined with respect to the mold axial direction.

[0278] In the fourth disclosed method for manufacturing a coil component,

[0279] The mold side surface located on the inner side in the mold radial direction of the pair of mold side surfaces may have an inclined surface inclined with respect to the mold axial direction.

[0280] In the fourth disclosed method for manufacturing a coil component,

[0281] The pair of mold side surfaces may each have an inclined surface inclined with respect to the mold axial direction.

[0282] In the fourth disclosed method for manufacturing a coil component,

[0283] The width of the top of the convex portion may be less than or equal to one half of the width of the convex portion at a connection position with the main body portion.

[0284] According to the fourth disclosure, the possibility of a decrease in the strength of the coil component due to the formation of the magnetic wall can be suppressed, and the coil component having the magnetic wall can be easily manufactured. BRIEF DESCRIPTION OF THE DRAWINGS

[0285] Figure 1 This is a diagram schematically showing a wireless power transmission system to which the coil components disclosed in the first to fourth aspects are applied.

[0286] Figure 2 It is a top view of the coil component according to the first embodiment of the first disclosure.

[0287] Figure 3 yes Figure 2 A perspective view of a portion of a coil component is shown.

[0288] Figure 4 It is along Figure 2 Cross-sectional view of the F4-F4 line.

[0289] Figure 5 It is along Figure 2 Cross-sectional view of the F5-F5 line.

[0290] Figure 6 It is used to manufacture Figure 2 A top view of the coil middle material of the coil part is shown.

[0291] Figure 7 Yes Description Figure 2FIG. 1 is a diagram showing an example of a method for manufacturing a coil component.

[0292] Figure 8 Yes Description Figure 2 FIG. 1 is a diagram showing an example of a method for manufacturing a coil component.

[0293] Fig. 9 Yes Description Figure 2 FIG. 1 is a diagram showing an example of a method for manufacturing a coil component.

[0294] Fig.10 Yes Description Figure 2 FIG. 1 is a diagram showing an example of a method for manufacturing a coil component.

[0295] Fig.11 Yes means Figure 6 FIG. 2 is a diagram showing a modified example of the coil intermediate material.

[0296] Fig.12 It is a cross-sectional view of a coil component according to a second embodiment of the first disclosure.

[0297] Fig.13 It is a perspective view of a coil component according to a third embodiment of the first disclosure.

[0298] Fig.14 yes Fig.13 A cross-sectional view of the coil parts is shown.

[0299] Fig.15 It means used for manufacturing Fig.13 A diagram of the coil intermediate material of the coil part shown.

[0300] Fig.16 It is a perspective view of a coil component according to a fourth embodiment of the first disclosure.

[0301] Fig.17 yes Fig.16 A cross-sectional view of the coil parts is shown.

[0302] Fig.18 It is a perspective view of a coil component according to a fifth embodiment of the first disclosure.

[0303] Fig.19 It is along Fig.18 Cross-sectional view of line F19-F19.

[0304] Fig. 20 It is along Fig.18 Cross-sectional view of the F20-F20 line.

[0305] Fig.21 Yes Description Fig.18 FIG. 1 is a diagram showing an example of a method for manufacturing a coil component.

[0306] Fig. 22 Yes Description Fig.18 FIG. 1 is a diagram showing an example of a method for manufacturing a coil component.

[0307] Fig.23 Yes Description Fig.18 FIG. 1 is a diagram showing an example of a method for manufacturing a coil component.

[0308] Fig.24 Yes Description Fig.18 FIG. 1 is a diagram showing an example of a method for manufacturing a coil component.

[0309] Fig.25 Yes Description Fig.18 FIG. 1 is a diagram showing an example of a method for manufacturing a coil component.

[0310] Fig.26 It is a top view of the coil component according to the first embodiment of the second disclosure.

[0311] Fig. 27 yes Fig.26 An exploded perspective view of the coil parts is shown.

[0312] Fig.28 yes Fig.26 A cross-sectional view of the coil parts is shown.

[0313] Fig.29 It is composed Fig.26 FIG. 1 is a top view of a first planar coil and a first holding component of a coil component.

[0314] Fig.30 It is along Fig.29 Cross-sectional view of the F30-F30 line.

[0315] Fig.31 It is overlooking Fig.30 A perspective view of the cross section shown.

[0316] Fig.32 It is along Fig.29 Cross-sectional view of the F32-F32 line.

[0317] Fig.33 It is along Fig.29 Cross-sectional view of the F33-F33 line.

[0318] Fig.34 It is used to manufacture Fig.26 A three-dimensional view of a mold for a coil part is shown.

[0319] Fig.35 It is along Fig.34 Cross-sectional view of the F35-F35 line.

[0320] Fig.36 It is along Fig.34 Cross-sectional view of the F36-F36 line.

[0321] Fig.37 It is along Fig.34 Cross-sectional view of line F37-F37.

[0322] Fig.38 Yes Description Fig.26 FIG. 1 is a diagram showing an example of a method for manufacturing a coil component.

[0323] Fig.39 Yes Description Fig.26 FIG. 1 is a diagram showing an example of a method for manufacturing a coil component.

[0324] Fig.40 Yes Description Fig.26 FIG. 1 is a diagram showing an example of a method for manufacturing a coil component.

[0325] Fig.41 It is a cross-sectional view of a coil component according to a second embodiment of the second disclosure.

[0326] Fig.42 It is used to manufacture Fig.41 A cross-sectional view of a mold for a coil part is shown.

[0327] Fig.43 Yes Description Fig.41 FIG. 1 is a diagram showing an example of a method for manufacturing a coil component.

[0328] Fig.44 Yes means Fig.42 A cross-sectional view of a modified example of the mold shown.

[0329] Fig.45 It is a top view of a coil component according to a third embodiment of the second disclosure.

[0330] Fig.46 It is along Fig.45 Cross-sectional view of the F46-F46 line.

[0331] Fig.47 It is along Fig.45 Cross-sectional view of line F47-F47.

[0332] Fig.48 It is a cross-sectional view of a coil component according to another embodiment of the second disclosure.

[0333] Fig.49 This is a cross-sectional view of a coil component according to still another embodiment of the second disclosure.

[0334] Fig.50 It is a top view of the coil component according to one embodiment of the third disclosure.

[0335] Fig.51 yes Fig.50 An exploded perspective view of the coil parts is shown.

[0336] Fig.52 yes Fig.50 A cross-sectional view of the coil parts is shown.

[0337] Fig.53 It is viewed from one side of the planar coil. Fig.52 A perspective view of the coil middle material is shown.

[0338] Fig.54 is viewed from one side of the outer surface of the first holding member Fig.53 A perspective view of the coil middle material is shown.

[0339] Fig.55 yes Fig.54 A top view of the coil center material is shown.

[0340] Fig.56 It is used for forming Fig.54 and Fig.55 A perspective view of a mold of a first retaining component is shown.

[0341] Fig.57 It is used to illustrate Fig.50 A cross-sectional view showing an example of a method for manufacturing a coil component shown in FIG.

[0342] Fig.58 It is a diagram for explaining a modified example of the coil component according to the fourth disclosure, and is a plan view showing the outer surface of the first holding member.

[0343] Fig.59 It means along Fig.58 FIG. 5 is a cross-sectional view of the first retaining component taken along line F59 - F50 .

[0344] Fig.60 It means along Fig.58 FIG. 5 is a diagram showing a cross section of the first holding component taken along line F60 - F60.

[0345] Fig.61 This is an exploded perspective view of a coil component according to one embodiment of the fourth disclosure.

[0346] Fig.62 yes Fig.61 A cross-sectional view of the coil part shown along the coil axis.

[0347] Fig.63 yes Fig.61 A top view of the coil middle material of the coil part is shown.

[0348] Fig.64 It is used to illustrate Fig.61A cross-sectional view showing an example of a method for manufacturing a coil component shown in FIG.

[0349] Fig.65 It is used to illustrate Fig.61 A cross-sectional view showing an example of a method for manufacturing a coil component shown in FIG.

[0350] Fig.66 It is used to illustrate Fig.61 A cross-sectional view showing an example of a method for manufacturing a coil component shown in FIG.

[0351] Fig.67 It is used to illustrate Fig.61 A cross-sectional view showing an example of a method for manufacturing a coil component shown in FIG.

[0352] Fig.68 is with Fig.62 The figure corresponding to the partially enlarged view of is a figure for explaining a modified example of the coil component of the fourth disclosure.

[0353] Fig.69 is with Fig.62 The figure corresponding to the partially enlarged view of is a figure used to explain another modified example of the coil component disclosed in the fourth disclosure.

[0354] Fig.70 is with Fig.62 The figure corresponding to the partially enlarged view of is a figure used to explain another modified example of the coil component disclosed in the fourth disclosure.

[0355] Fig.71 is with Fig.62 The figure corresponding to the partially enlarged view of is a figure used to explain another modified example of the coil component disclosed in the fourth disclosure.

[0356] Fig.72 is with Fig.62 The figure corresponding to the partially enlarged view of is a figure used to explain another modified example of the coil component disclosed in the fourth disclosure.

[0357] Fig.73 is a table showing the results of the simulation.

[0358] Fig.74 It is a graph which shows the result of simulation.

[0359] Fig.75 is with Fig.62 The figure corresponding to the local enlarged view is an enlarged view of a local cross-section of a coil part in which the width of the wall portion is uniform along the axial direction of the coil.

[0360] Fig.76 is with Fig.64 The corresponding figure is used to illustrate Fig.75 A diagram showing a method for manufacturing a coil component. DETAILED DESCRIPTION

[0361] Hereinafter, each embodiment will be described with reference to the drawings.

[0362] It should be noted that in this specification, the terms "sheet", "film", "plate" and the like are not distinguished from each other only based on the difference in the name. Therefore, for example, "sheet" is a concept that also includes a component that can also be called a film or a plate.

[0363] Figure 1 The wireless power transmission system S to which the coil components 10, 1010, 2010, and 3010 of the first to fourth disclosures are applied is schematically shown. Figure 1 A wireless power transmission system S (hereinafter, simply referred to as a power transmission system S) will be described.

[0364] <Wireless power transmission system>

[0365] The power transmission system S includes a power transmission device 1 and a power receiving device 2. The power transmission device 1 includes a coil component 10, 1010, 2010, or 3010, and a high-frequency current supply unit 1A. The coil component 10, 1010, 2010, or 3010 in the power transmission device 1 functions as a power transmission coil. The high-frequency current supply unit 1A supplies a high-frequency current to the coil component 10, 1010, 2010, or 3010 serving as the power transmission coil.

[0366] The power receiving device 2 includes a coil component 10, 1010, 2010 or 3010, and a conversion unit 2A. The coil component 10, 1010, 2010 or 3010 in the power receiving device 2 functions as a power receiving coil. The conversion unit 2A shapes the high-frequency current generated by the coil component 10, 1010, 2010 or 3010. The conversion unit 2A includes a rectifier circuit that converts the high-frequency current into a direct current. The conversion unit 2A may also be configured to include, for example, a full-wave rectifier circuit including a plurality of diodes and a smoothing capacitor.

[0367] In the present embodiment, power transmission device 1 and power reception device 2 each include coil component 10, 1010, 2010, or 3010. However, only one of power transmission device 1 and power reception device 2 may use coil component 10, 1010, 2010, or 3010, and the other may use a coil component of a different type.

[0368] When power is transmitted wirelessly (contactlessly) from the power transmission device 1 to the power receiving device 2, the power transmission device 1 supplies a high-frequency current of a predetermined frequency from the high-frequency current supply unit 1A to the coil component 10, 1010, 2010, or 3010 as the power transmission coil. At this time, a magnetic field is generated in the coil component 10, 1010, 2010, or 3010 by electromagnetic induction. Then, due to the influence of the magnetic field, a high-frequency current is generated in the coil component 10, 1010, 2010, or 3010 as the power receiving coil in the power receiving device 2. That is, the power receiving device 2 receives the magnetic field from the power transmission device 1 or is affected by the magnetic field in the power transmission device 1, and the high-frequency current flows by electromagnetic induction. The conversion unit 2A converts the high-frequency current into a direct current, and supplies the converted direct current to, for example, a storage battery (not shown).

[0369] Figure 1 The power transmission system S shown adopts a magnetic field resonance method as a power transmission method. However, the coil components 10, 1010, 2010, and 3010 of the present embodiment can also be used in a power transmission system of an electromagnetic induction method. In addition, the power transmission system S is configured as a system for wirelessly transmitting power to an electric vehicle. In this case, the power transmission device 1 is set on a road, a parking lot, etc. The power receiving device 2 is set in the electric vehicle.

[0370] However, the use of the power transmission system S is not limited to power transmission to electric vehicles. For example, the power transmission system S can also be used to transmit power to flying objects such as drones and robots. In addition, the power transmission system S can also be used to transmit power to submarines in the sea and exploration robots. In this way, the power transmission system S can be used to transmit power to various mobile objects such as electric vehicles, flying objects, robots, submarines, etc. In addition, the use of coil parts 10, 1010, 2010, 3010 is not limited to wireless power transmission systems. For example, coil parts 10, 1010, 2010, 3010 can also be used for transformers, DC-DC converters, antennas, etc.

[0371] <<<First disclosed embodiment>>>

[0372] Hereinafter, embodiments of the first disclosure will be described with reference to the drawings.

[0373] <<First embodiment of the first disclosure>>

[0374] <Coil parts>

[0375] Hereinafter, coil component 10 according to the first embodiment will be described. Figure 2 It is a top view of coil component 10 . Figure 3 This is a perspective view of a portion of the coil component 10, specifically, a top view along the Figure 2A perspective view of a portion of the coil component 10 cut along line F5 - F5. Figure 4 It is along Figure 2 Cross-sectional view of the F4-F4 line. Figure 5 It is along Figure 2 Cross-sectional view of the F5-F5 line.

[0376] like Figures 2 to 5 As shown, the coil device 10 includes a first planar coil 11 , a first holding member 20 , a first connecting terminal 51 , and a second connecting terminal 52 .

[0377] The first holding member 20 overlaps with the first planar coil 11 and holds the first planar coil 11. That is, the first holding member 20 and the first planar coil 11 are integrated. Figure 2 In FIG. 1 , first connection terminal 51 and second connection terminal 52 are simply indicated by two-dot chain lines. Hereinafter, each part of coil device 10 will be described in detail.

[0378] (First Planar Coil)

[0379] The first planar coil 11 is spiral-shaped and is made of a conductive material. In the present embodiment, the first planar coil 11 contains copper. Specifically, the first planar coil 11 is made of copper. However, the first planar coil 11 may be made of a copper alloy, aluminum, an aluminum alloy, or the like.

[0380] like Figure 2 and Figure 3 As shown, the first planar coil 11 is plate-shaped, and the cross-sectional shape of the first planar coil 11 in a direction perpendicular to the direction in which the first planar coil 11 is wound in a spiral shape (in other words, the direction in which the first planar coil 11 extends in a spiral shape) is rectangular.

[0381] Figure 2 The reference symbol C1 shown in the figure represents the central axis of the first planar coil 11 passing through the center of the spiral shape of the first planar coil 11. Hereinafter, when the axial direction of the first planar coil 11 is referred to, the direction is a direction extending on the central axis C1 or a direction parallel to the central axis C1. In addition, the direction orthogonal to the central axis C1 is referred to as the radial direction of the first planar coil 11. The first planar coil 11 includes a first surface 11A and a second surface 11B opposite to each other in the axial direction. The first planar coil 11 is opposite to the first holding member 20 on the second surface 11B.

[0382] like Figure 2As shown, the first planar coil 11 has a conductor 11E in a spiral shape formed by a plurality of turns 11n. The plurality of turns 11n of the first planar coil 11 are arranged in a direction (radial direction) orthogonal to the central axis C1 of the spiral shape. Specifically, the plurality of turns 11n are connected so as to gradually move away from the central axis C1 of the spiral shape toward the radial direction outward. Then, a spiral shape is formed thereby.

[0383] The turn 11n is basically a linear conductor portion that is not formed into a ring shape and is wound 360 degrees around the central axis C1. In the case of a so-called planar coil, both ends of the turn 11n are deviated in the radial direction. Among the plurality of turns 11n, the radially outer end of a certain turn 11n is connected to the radially inner end of another turn 11n, and the other turn 11n extends away from the central axis C1.

[0384] Hereinafter, the turn portion closest to the center axis C1 among the plurality of turns 11n is sometimes referred to as the turn portion 111. In addition, the turn portion connected to the turn portion 111 is sometimes referred to as the turn portion 112. In the present embodiment, the plurality of turns 11n is composed of five turns 111 to 115. Hereinafter, when describing the common items in each of the plurality of turns 11n, they are basically referred to as the turn portion 11n.

[0385] In the present embodiment, the turn 11n is wound in a rectangular shape. However, the turn 11n may be wound in a polygonal shape other than a rectangular shape. For example, the turn 11n may be wound in an octagonal shape, a regular octagonal shape, a dodecagonal shape, or a regular dodecagonal shape. Furthermore, the turn 11n may be wound in a circular shape. It should be noted that the vortex shape mentioned in this specification and the present disclosure refers to the shape of a plane curve wound in a spiral shape. The plane curve mentioned here also includes a plane pattern that is bent into a broken line shape as shown in the figure and is repeatedly wound. In addition, in other words, the vortex shape is a shape that is wound in a manner that is gradually located on the outside around the central axis C1 of the first planar coil 11.

[0386] The radially inner end (the end close to the center axis C1) of the turn 111 closest to the center axis C1 is electrically connected to the first connection terminal 51. On the other hand, the radially outer end (the end away from the center axis C1) of the turn 115 farthest from the center axis C1 among the plurality of turns 11n is connected to the second connection terminal 52.

[0387] Here, the radial inner side of the first planar coil 11 (turn 11n) refers to the direction close to the central axis C1 in the radial direction. In addition, the radial outer side of the first planar coil 11 (turn 11n) refers to the direction away from the central axis C1 in the radial direction. In addition, in the present embodiment, the central axis C1 is determined as follows. First, from the radial inner end of the turn 112 adjacent to the innermost turn 111, linear imaginary turns of a shape similar to the turn 112 are sequentially drawn in a manner to form a vortex shape in the radial inner side. Then, the drawing is continued until an imaginary turn contained within a diameter of 1 cm can be drawn. Then, a line passing through the radial inner area of ​​the imaginary turn contained within a diameter of 1 cm in a direction orthogonal to the circumferential and radial directions of the vortex shape is determined as the central axis C1.

[0388] In addition, refer to Figure 3 , Figure 4 The first planar coil 11 in this embodiment further includes a protruding piece 11T extending from the inner periphery and / or outer periphery of the turn portion 11n and bent in the axial direction so as to be away from the turn portion 11n. The protruding piece 11T is connected in a state of being hooked on the first holding member 20. Therefore, in the coil component 10 of this embodiment, the first planar coil 11 is not easily deviated relative to the first holding member 20. The details of this protruding piece 11T will be described later.

[0389] As an example, the first planar coil 11 of the present embodiment is formed by punching a copper plate into a spiral shape.

[0390] The thickness of the first planar coil 11 (the thickness of the conductor 11E) may be, for example, not less than 0.1 mm and not more than 1.0 mm. In addition, the radius of the first planar coil 11 (the distance from the central axis C1 to the portion farthest from the central axis C1 in the radial direction) may be not less than 80 mm, or not less than 80 mm and not more than 450 mm. In addition, the aspect ratio of the first planar coil 11 (conductor 11E) having a rectangular cross-sectional shape is determined by dividing the line width (the width of each turn 11n in the radial direction) of the first planar coil 11 (conductor 11E) by the thickness of the first planar coil 11 (conductor 11E). The aspect ratio of the first planar coil 11 (conductor 11E) may be not more than 40, or not less than 2 and not more than 12, or not less than 3 and not more than 10.

[0391] In the case of transmitting electric power to an electric vehicle by magnetic field resonance, it is preferred that an electric power of more than 1 kW, preferably more than 5 kW, can be transmitted in a frequency band of high-frequency current of preferably 10 kHz to 200 kHz, particularly above 75 kHz and below 100 kHz, and further 79 kHz to 90 kHz. In this case, the thickness of the first planar coil 11 formed of copper is preferably more than 0.2 mm. From this point of view, the lower limit of the thickness of the first planar coil 11 can also be set to 0.2 mm. In addition, in the case of transmitting electric power to an electric vehicle, it is not desired that the size is too large, and sometimes the size is limited. From this point of view, the first planar coil 11, in detail, the conductor 11E of the first planar coil 11 is preferably formed in a size that is accommodated in a square with a side of 800 mm.

[0392] In addition, the line width of the first planar coil 11 (the line width of the conductor 11E), that is, the radial width (radial width) of each turn portion 11n is not particularly limited. However, for example, when considering that an electric power of more than 1 kW, preferably more than 5 kW, can be transmitted in the frequency band of high-frequency current of 79 kHz to 90 kHz, the radial width of the turn portion 11n can be more than 2 mm and less than 20 mm, or more than 2 mm and less than 16 mm, more than 2 mm and less than 12 mm, or more than 2 mm and less than 8 mm. In addition, the number of turns of the first planar coil 11 can also be more than 4 and less than 12, but there is no particular limitation.

[0393] (First Holding Member)

[0394] The first holding member 20 overlaps the first planar coil 11 in a manner opposite to the second surface 11B of the first planar coil 11, and holds the first planar coil 11. The first holding member 20 includes a first surface 20A and a second surface 20B opposite to each other extending in the radial direction of the first planar coil 11, and the first surface 20A is a surface overlapping the first planar coil 11. When the first planar coil 11 and the first holding member 20 are overlapped, the plurality of turns 11n of the first planar coil 11 are respectively in contact with the first holding member 20. It should be noted that the first surface 20A overlapping the first planar coil 11 refers to a surface including a surface in contact with the first planar coil 11 and a surface facing the same direction as the first surface and not in contact with the first planar coil 11.

[0395] In the coil component 10, for example, when transmitting power, the magnetic field generated in the first planar coil 11 may pass through the first holding member 20. In the present embodiment, it is assumed that the magnetic field passes through the first holding member 20. Therefore, in order not to hinder the magnetic field and in order not to generate eddy current, the first holding member 20 is preferably non-conductive (insulating) and non-magnetic.

[0396] Considering that it is preferably non-conductive (insulating) and non-magnetic, the material of the first holding member 20 is, for example, a resin, or a fiber-reinforced plastic. More specifically, the material of the first holding member 20 may also be glass fiber reinforced polyamide. However, there is no particular limitation on the material of the first holding member 20. For example, it may not contain glass fiber. In addition, thermoplastic resins or thermosetting resins other than polyamide may also be used. It should be noted that insulation refers to a volume resistivity of 10 10 Ω·m or more. Nonmagnetic means not showing magnetism.

[0397] The holding of the first planar coil 11 by the first holding member 20 is performed by integrating the first holding member 20 and the first planar coil 11. In the present embodiment, the first planar coil 11 and the first holding member 20, strictly speaking, the forming materials thereof, are hot stamped to integrate the first planar coil 11 and the first holding member 20. This integration is performed, for example, by the first holding member 20 engaging with the concavo-convex surface of the first planar coil 11 which is metal.

[0398] Here, the first planar coil 11 and the first holding member 20 are made of different materials, so there is a possibility that a strong adhesion cannot be obtained. Therefore, the first planar coil 11 in this embodiment includes the above-mentioned protruding piece 11T. In addition, the first holding member 20 includes a groove 22 on the first surface 20A, and the protruding piece 11T is connected to the inner surface of the groove 22 in a manner of hooking.

[0399] like Figure 2 As shown in FIG. 1 , the groove 22 extends in a spiral shape along the turn 11n. Specifically, the groove 22 extends from the radially inner position of the innermost turn 111 along the turn 111 and then passes through the adjacent turns 11n in sequence. The cross-sectional shape of the groove 22 when cut along the radial direction is a rectangular shape, as shown in FIG. Figure 3 and Figure 4 As shown, the inner surface of the groove 22 includes a bottom surface 22A and a pair of side surfaces 22B rising from the bottom surface 22A. However, the shape of the groove 22 is not particularly limited. For example, the groove 22 in the present embodiment is formed in a spiral shape, for example, the groove 22 can also be formed intermittently along the circumferential direction between adjacent turns 11n. In addition, the cross-sectional shape of the groove 22 can also be a trapezoidal shape or a triangular shape.

[0400] (Connection terminal)

[0401] like Figure 2As shown, the first connection terminal 51 is connected to the radial inner end of the turn 111 in the first planar coil 11. The second connection terminal 52 is connected to the radial outer end of the turn 115 in the first planar coil 11. The first connection terminal 51 and the second connection terminal 52 can be used, for example, when connecting to the high-frequency current supply unit 1A or the conversion unit 2A. The connection between the first connection terminal 51 and the turn 111 and the connection between the second connection terminal 52 and the turn 115 can also be performed by ultrasonic bonding. However, there is no limitation on the connection method, and for example, a connection based on a conductive adhesive can also be used.

[0402] <Protruding piece in the first planar coil>

[0403] The protruding piece 11T is described in detail below. Figures 2 to 4 As shown, the protruding piece 11T extends from the inner periphery and / or outer periphery of at least one of the plurality of turns 11n and is bent in the axial direction to be separated from the turn 11n. In this embodiment, as an example, the protruding piece 11T is provided on all the turns 11n.

[0404] In detail, in the innermost turn 111, a plurality of protruding pieces 11T extend only from the outer periphery. In the other turns 112 to 115, a plurality of protruding pieces 11T extend from the inner periphery and the outer periphery of each of the turns 112 to 115. The plurality of protruding pieces 11T provided in each turn 11n are provided at intervals in the circumferential direction. In addition, the plurality of protruding pieces 11T provided in the plurality of turns 11n include a group of protruding pieces 11T arranged side by side in the radial direction. In the example shown in the figure, the group of protruding pieces 11T arranged side by side in the radial direction is formed at intervals of 90 degrees in the circumferential direction. However, the number and formation positions of the protruding pieces 11T are not particularly limited.

[0405] It should be noted that the inner circumference of the turn portion 11n is the portion of the turn portion 11n facing the central axis C1 side (radially inward), and the outer circumference of the turn portion 11n is the portion of the turn portion 11n facing away from the central axis C1 (radially outward). Figure 2 In the figure, for convenience of explanation, the inner peripheral edge of the outermost turn portion 115 is represented by the reference numeral 11i, and the outer peripheral edge of the turn portion 115 is represented by the reference numeral 11e.

[0406] The protruding piece 11T is connected to the inner surface of the slot 22 in a manner hooked thereon as described above. Specifically, the protruding piece 11T is connected to the inner surface of the slot 22 in the radial direction. The first planar coil 11 of the present embodiment overlaps with the first holding member 20 in a manner that each turn portion 11n is connected to a portion of the first holding member 20 where the slot 22 is not formed. That is, each turn portion 11n is located outside the slot 22. In this state, as an example, the protruding piece 11T is bent at a right angle from the turn portion 11n, extends toward the bottom surface 22A of the slot 22, and is connected to the side surface 22B of the slot 22.

[0407] In more detail, if we compare Figure 4 and Figure 5 It can be seen that in this embodiment, the groove 22 includes a recessed portion 23 on the side 22B, and at least a portion (in this embodiment, the entire portion) of the protruding piece 11T is located in the recessed portion 23. In other words, at least a portion of the protruding piece 11T is embedded in the recessed portion 23 and embedded in the first holding member 20. The inner surfaces of the protruding piece 11T and the recessed portion 23 are preferably joined by an anchoring effect, but the protruding piece 11T and the recessed portion 23 may be in contact with or close to each other. In addition, the recessed portion 23 may not be formed in the groove 22, and the protruding piece 11T may be in contact with the side 22B of the flat groove 22.

[0408] In the present embodiment, the protruding piece 11T extends in a manner bent at a right angle from the turn portion 11n, but the protruding piece 11T may extend in an inclined direction from the turn portion 11n toward the bottom surface 22A of the groove 22. In addition, in the present embodiment, the protruding piece 11T does not reach the bottom surface 22A, but the protruding piece 11T may be formed to be in contact with the bottom surface 22A or buried in the bottom surface 22A.

[0409] The length of the tip portion of the protruding piece 11T from the second surface 11B in the turn portion 11n may be, for example, 1 mm or more, 1.5 mm or more, or 2 mm or more. From the viewpoint of suppressing the misalignment of the first planar coil 11 and the first holding member 20, the length of the protruding piece 11T is preferably, for example, 1 mm or more, but if it is too long, it is sometimes not preferred from the viewpoint of the flow of current, and may be, for example, 20 mm or less, or 15 mm or less. However, there is no particular limitation on the size and shape of the protruding piece 11T.

[0410] In addition, if Figure 3 and Figure 4As shown, the turn portion 11n has a through hole 11H at a position adjacent to the protruding piece 11T in the radial direction. Moreover, the through hole 11H overlaps with the recessed portion 24 formed in the portion of the first holding member 20 where the groove 22 is not formed. Although described later, the first planar coil 11 and the first holding member 20 are integrated by hot stamping using a mold 200. During the hot stamping, the positioning protrusion 204 formed in the mold 200 passes through the through hole 11H of the first planar coil 11. The recessed portion 24 is a hole formed by burying the positioning protrusion 204 in the forming material forming the first holding member 20 and is generated due to the manufacturing process. Such a through hole 11H and the recessed portion 24 may not be provided.

[0411] <Method of Manufacturing Coil Component 10>

[0412] Below, refer to Figures 6 to 11 An example of a method for manufacturing coil component 10 will be described.

[0413] Figure 6 1 is a top view of a coil intermediate material 11M for manufacturing the coil component 10. When manufacturing the coil component 10, the coil intermediate material 11M is prepared. The coil intermediate material 11M is a component corresponding to the intermediate material of the first planar coil 11. In detail, the first planar coil 11 is formed by further punching the coil intermediate material 11M punched out from a copper plate.

[0414] The coil intermediate material 11M includes a plurality of turns 11n arranged in the radial direction, a plurality of connecting portions 11S connecting the turns 11n adjacent in the radial direction, and a frame portion 11F positioned so as to surround the outermost turns 115 and connected to the connecting portion 11S extending from the outer periphery of the turns 115. In more detail, the first planar coil 11 is formed by separating the frame portion 11F from the coil intermediate material 11M and separating the connecting portion 11S from any one of the adjacent turns 11n connected to the connecting portion 11S. The plurality of connecting portions 11S include a group of connecting portions 11S arranged side by side in the radial direction, and in the example shown in the figure, the group of connecting portions 11S arranged side by side in the radial direction is formed at intervals of 90 degrees in the circumferential direction. However, the number and formation positions of the connecting portions 11S are not particularly limited. The connecting portion 11S is provided to suppress the warping of the coil intermediate material 11M.

[0415] In addition, when manufacturing the coil component 10, Figure 7 and Figure 8 As shown, a mold 200 is prepared. Figure 7 A perspective view showing a portion of the mold 200, Figure 8The cross section of the mold 200 is schematically shown. The mold 200 includes a plate-shaped main body 201 having a flat installation surface 200S on which the first planar coil 11 is placed. A convex portion 202 is formed on the main body 201, and the convex portion 202 protrudes from the installation surface 200S and extends in a spiral shape. Figure 4 and Figure 5 The convex portion 202 is a portion forming the groove 22 of the first holding member 20. In addition, in the present embodiment, the plurality of positioning protrusions 204 are formed at appropriate positions of the portion of the main body portion 201 where the convex portion 202 is not formed, that is, the installation surface 200S.

[0416] After the coil intermediate material 11M and the mold 200 are prepared as described above, the coil intermediate material 11M is placed in the mold 200. Figure 7 and Figure 8 As shown, the coil intermediate material 11M is placed in the mold 200 in such a manner that the connection portion 11S faces the convex portion 202 in the mold 200, and the adjacent turn portions 11n connected by the connection portion 11S face the portion (setting surface 200S) of the mold 200 different from the convex portion 202. Moreover, by placing the first planar coil 11 in such a manner that the connection portion 11S is in contact with the convex portion 202, the turn portion 11n is in a state of floating from the setting surface 200S. In addition, the first planar coil 11 is placed in the mold 200 in such a manner that the positioning protrusion 204 passes through the through hole 11H formed in the turn portion 11n.

[0417] Then, if Figure 8 As shown, the forming material 220 is set on the coil intermediate material 11M. Then, the coil intermediate material 11M and the forming material 220 are hot stamped between the mold 200 and another mold not shown. During the hot stamping, the forming material 220 softens and becomes a molten state. In addition, the forming material 220 is pushed into the mold 200 via the coil intermediate material 11M. At this time, the protrusion 202 is relatively pressed into the forming material 220 via the connecting portion 11S. As a result, the protrusion 202 and the positioning protrusion 204 are buried in the forming material 220, and the forming material 220 is filled to the setting surface 200S. Then, at this time, in the present embodiment, the connecting portion 11S is pressed by the protrusion 202, as shown in FIG. Fig. 9 As shown, the connecting portion 11S is separated from any one of the adjacent turns 11n connected thereto and is bent away from the turns 11n. Thus, the connecting portion 11S is separated from any one of the adjacent turns 11n connected thereto, and the separated connecting portion 11S forms a protruding piece 11T.

[0418] In this embodiment, the middle position of the radial direction of the connecting portion 11S is cut off, thereby forming a protruding piece 11T extending from the outer peripheral edge of the inner turn portion 11n and a protruding piece 11T extending from the inner peripheral edge of the outer turn portion 11n by the connecting portion 11S connected to the adjacent turn portion 11n. When a pair of protruding pieces 11T are formed by the connecting portion 11S in this way, it is necessary to cut the middle position of the radial direction of the connecting portion 11S using the mold 200. In order to properly perform such cutting, for example, Fig.11 As shown, the connection portion 11S may include a narrowed portion 11Sa having a partially reduced cross-sectional area at a position in the middle of the connection portion 11S in the radial direction.

[0419] After hot stamping as described above, the forming material 220 is solidified to form the first holding member 20 integrated with the first planar coil 11. The first holding member 20 is formed with a groove 22 formed by embedding the convex portion 202 in the forming material 220 and a recessed portion 24 formed by embedding the positioning protrusion 204. Fig.10 As shown, the coil component 10 is obtained by removing the first planar coil 11 and the first holding member 20 from the mold 200. It should be noted that the manufacturing method described above is an example. For example, the first planar coil 11 and the first holding member 20 can also be integrated by injecting a molding material between the mold 200 and another mold not shown.

[0420] <Applications of coil parts>

[0421] The coil component 10 of the present embodiment can be used as a power transmission coil in the power transmission device 1 of the wireless power transmission system S described above, and can be used as a power reception coil in the power reception device 2 .

[0422] When the coil component 10 is used as a power transmission coil, the first connection terminal 51 and the second connection terminal 52 are connected to Figure 1 When a high-frequency current is supplied to the coil component 10, the current can flow from the first connection terminal 51 to the high-frequency current supply unit 1A or the AC power supply via the first planar coil 11 and the second connection terminal 52. In addition, the current can flow from the second connection terminal 52 to the high-frequency current supply unit 1A or the AC power supply via the first planar coil 11 and the first connection terminal 51. Thus, a magnetic field including magnetic lines of force along the central axis of the planar coil can be generated.

[0423] On the other hand, when the coil component 10 is used as a power receiving coil, a magnetic field including magnetic lines of force is received or generated by passing through the inner side of the first planar coil 11, thereby enabling the first planar coil 11 to generate a high-frequency current. Furthermore, the high-frequency current can be supplied from the first connection terminal 51 or the second connection terminal 52 to an external device.

[0424] In addition, the coil component 10 can also be used in a transformer, an antenna, etc. For example, when the coil component 10 functions as a primary coil in a transformer, the first connection terminal 51 and the second connection terminal 52 are connected to an AC power source. Then, by supplying a high-frequency current, a magnetic flux can be supplied from the center side of the planar coil to the iron core.

[0425] The coil component 10 of the present embodiment described above includes a first planar coil 11 including a plurality of turns 11n and a protruding piece 11T extending from the inner periphery and / or the outer periphery of at least one of the plurality of turns 11n and bent away from the turns 11n, and a first holding member 20, and the first holding member 20 overlaps the first planar coil 11 in a state of being in contact with the plurality of turns 11n of the first planar coil 11. Furthermore, the first holding member 20 includes a groove 22 on a first surface 20A on which the first planar coil 11 is overlapped, and the protruding piece 11T is in contact with the inner surface of the groove 22 in the radial direction.

[0426] In the coil component 10, the protruding piece 11T is in contact with the inner surface of the slot 22 in the radial direction. Thus, the first planar coil 11 can be prevented from floating and deviating from the first holding component 20, which is a component integrated with the first planar coil 11. In particular, in the present embodiment, by forming the protruding piece 11T using the connecting portion 11S, which is a component that mainly performs its original function in the manufacturing process, the protruding piece 11T can be formed efficiently and at low cost. In addition, when forming the first holding component 20, in particular, the connecting portion 11S is cut using the mold 200 used in the forming, so that the manufacturing efficiency of the coil component 10 can be improved. That is, the first holding component 20 can also be formed after the connecting portion 11S of the coil intermediate material 11M is cut, but in the present embodiment, the manufacturing efficiency can be greatly improved compared to the manufacturing based on this order.

[0427] In addition, by connecting the protruding piece 11T to the inner periphery and / or outer periphery of the turn 11n, the protruding piece 11T can be prevented from having an adverse effect on the flow of current in the turn 11n. Therefore, according to the present embodiment, it is possible to suppress the deviation of the first planar coil 11 from the first retaining member 20 while suppressing the reduction in the performance of the coil component 10. In fact, in the experiments and simulations of the inventors of the present application, it was not confirmed that the protruding piece 11T damaged the performance of the coil component 10. However, if the number of protruding pieces 11T is too large, there is a concern that the impact on the performance of the coil component 10 will become greater. From this point of view, for example, the proportion of the connection portion of the protruding piece 11T in a turn 11n relative to the total length of a turn 11n can also be set to less than 20%, less than 10%, less than 5%, etc.

[0428] In addition, in the present embodiment, the groove 22 includes a recessed portion 23, and at least a portion of the protruding piece 11T is located in the recessed portion 23. Thus, the first planar coil 11 can be effectively prevented from deviating from the first holding member 20. In addition, the protruding piece 11T extends from the inner peripheral edge and the outer peripheral edge of the turn portion 11n, respectively. Accordingly, the first planar coil 11 can also be effectively prevented from deviating from the first holding member 20.

[0429] <<Second embodiment of the first disclosure>>

[0430] Next, a coil device 10a according to a second embodiment will be described. Fig.12 It is a partial cross-sectional view of the coil device 10a of the second embodiment. It should be noted that the same reference numerals are given to the components of the embodiment described below that are the same as or correspond to the first embodiment of the first disclosure. In the case of the same structure, the detailed description thereof is omitted.

[0431] The coil component 10a of the second embodiment includes, in addition to the first planar coil 11 and the first holding member 20 described in the first embodiment, a second holding member 30. The second holding member 30 is integrated with the first planar coil 11 and the first holding member 20 in a manner of clamping the first planar coil 11 with the first holding member 20. In addition, the second holding member 30 of the present embodiment has magnetism. In detail, the second holding member 30 has magnetism, has high resistance, and preferably has insulation. However, the second holding member 30 may also have insulation without magnetism.

[0432] The second holding member 30 is described in detail. The second holding member 30 includes a main body portion 31 and a wall portion 32. The main body portion 31 is connected to the first surface 11A opposite to the second surface 11B in the first planar coil 11 and is connected to the first holding member 20, and extends in a sheet-like manner. The wall portion 32 passes between adjacent turns 11n from the main body portion 31 and fills the groove 22. The second holding member 30 as a whole has magnetism, and the wall portion 32 also has magnetism. By forming the magnetic wall portion 32 in a manner protruding from the first planar coil 11, the performance of the coil component 10a can be improved.

[0433] The relative magnetic permeability of the second holding member 30 is preferably 2.0 or more, and may be 2.0 or more and 10.0 or less. The relative magnetic permeability of the second holding member 30 is more preferably 5.0 or more, and may be 5.0 or more and 10.0 or less. There is no particular limitation on the relative magnetic permeability of the second holding member 30, but if it is too large, the flexibility or strength of the second holding member 30 may be undesirably damaged. Therefore, the relative magnetic permeability of the second holding member 30 may also be 200 or less.

[0434] In addition, by providing the second holding member 30 with a wall portion 32, the coil performance can be effectively improved. There is no particular limitation on the height of the wall portion 32 from the base connected to the first planar coil 11 to the front end, and for example, it can be greater than 0.5 mm, or greater than 1.0 mm. There is a tendency that the higher the height of the wall portion 32, the higher the effect of suppressing eddy current loss and the higher the coupling coefficient. On the other hand, there is a tendency that the higher the wall portion 32, the easier it is to be damaged starting from the lower part. Therefore, the height of the wall portion 32, for example, can also be less than 10 mm.

[0435] As an example, the second holding member 30 of the present embodiment includes a resin and a plurality or countless magnetic particles made of a magnetic body. The magnetic particles are held in the resin as a holding material. The resin is non-magnetic and insulating.

[0436] The magnetic particles can also be formed by any one or more of ferrite, particularly ferrite of soft magnetic material, nanocrystalline magnetic body, silicon steel, electromagnetic soft iron, and amorphous metal. The resin used as the holding material can also be glass fiber reinforced polyamide. That is, the resin can also be formed by a material containing polyamide and glass fiber as a thermoplastic resin (thermoplastic material). However, the molding material of the second holding member 30 is not particularly limited, for example, the resin contained in the second holding member 30 can also be a thermosetting resin.

[0437] According to the second embodiment as described above, the first planar coil 11 is reliably suppressed from being displaced from the first holding member 20 by the second holding member 30. In addition, since the second holding member 30 has magnetism, the performance of the coil device 10a can be improved.

[0438] <<Third embodiment of the first disclosure>>

[0439] Next, a coil device 10b according to a third embodiment will be described. Fig.13 It is a perspective view of the coil device 10 b according to the third embodiment, and more specifically, it is a perspective view of the first planar coil 11 constituting the coil device 10 b . Fig.14 It is a partial cross-sectional view of the coil device 10b. It should be noted that the same reference numerals are given to the same or corresponding parts in the first and second embodiments of the first disclosure in the following embodiments. In the case of the same structure, the detailed description thereof is omitted.

[0440] like Fig.13 and Fig.14 As shown in FIG. 1 , in this embodiment, the protruding piece 11T extends only from the inner peripheral edge of the turn portion 11n. Although not shown in the figure, a plurality of protruding pieces 11T extend from the inner peripheral edge of a turn portion 11n, and these plurality of protruding pieces 11T are arranged at intervals in the circumferential direction. Fig.13 The first holding member 20 is omitted in the figure, but in fact, the first holding member 20 is located Fig.13 Above the first planar coil 11 in the embodiment.

[0441] Fig.15 The coil intermediate material 11M for forming the first planar coil 11 in the coil component 10b is shown. In this embodiment, the connecting portion 11S in the coil intermediate material 11M has a narrowed portion 11Sa whose cross-sectional area is locally reduced. The narrowed portion 11Sa is formed at the inner end of the connecting portion 11S in the radial direction.

[0442] In the above-described embodiment, the connection portion 11S can be formed relatively easily. In addition, the displacement suppression effect can be obtained by ensuring a large length of one connection portion 11S. It should be noted that in this embodiment, the second holding member 30 described in the second embodiment can also be used.

[0443] <<Fourth embodiment of the first disclosure>>

[0444] Next, a coil component 10c according to a fourth embodiment will be described. Fig.16 It is a perspective view of the coil component 10c according to the fourth embodiment, and more specifically, it is a perspective view of the first planar coil 11 constituting the coil component 10c. Fig.17 It is a partial cross-sectional view of the coil device 10c. It should be noted that the same reference numerals are given to the same or corresponding parts in the first to third embodiments of the first disclosure in the following embodiments. In the case of the same structure, the detailed description thereof is omitted.

[0445] like Fig.16 and Fig.17 As shown, in this embodiment, the protruding piece 11T extends only from the outer peripheral edge of the turn portion 11n. Although not shown in the figure, a plurality of protruding pieces 11T extend from the outer peripheral edge of one turn portion 11n, and these plurality of protruding pieces 11T are arranged at intervals in the circumferential direction. Fig.16 The first holding member 20 is omitted in the figure, but in fact, the first holding member 20 is located Fig.16 Above the first planar coil 11 in the embodiment.

[0446] The protruding piece 11T in this embodiment includes a first portion 11T1 extending from the turn portion 11n along the side surface 22B of the groove 22 and a second portion 11T2 bent from the front end of the first portion 11T1 and extending along the bottom surface 22A of the groove 22. The second portion 11T2 is located in a recessed portion formed in the bottom surface 22A.

[0447] It should be noted that, although not shown in the figure, the coil intermediate material for forming the first planar coil 11 in the coil component 10c includes the same connecting portion 11S as in the third embodiment, and a narrowing portion 11Sa is formed in the connecting portion 11S. However, the narrowing portion 11Sa is formed at the outer end of the connecting portion 11S in the radial direction.

[0448] In the above-described embodiment, the same effect as in the third embodiment is obtained. In addition, when an alternating current flows through the first planar coil 11, usually, the current density of the inner peripheral side of the turn portion 11n is greater than the current density of the outer peripheral side. Therefore, in this embodiment, the adverse effect of the protruding piece 11T on the flow of current can be effectively suppressed. It should be noted that in this embodiment, the second holding member 30 described in the second embodiment can also be used.

[0449] <<Fifth embodiment of the first disclosure>>

[0450] Next, a coil device 10d according to a fifth embodiment will be described. Fig.18 It is a perspective view of a coil device 10d according to a fifth embodiment. Fig.19 It is along Fig.18 A cross-sectional view of the coil part 10d of the F19-F19 wire, Fig. 20 It is along Fig.18 10d of the coil component of the F20-F20 wire. It should be noted that the same reference numerals are given to the same or corresponding parts in the first to fourth embodiments of the first disclosure in the following embodiments. In the case of the same structure, the detailed description thereof is omitted.

[0451] like Figures 18 to 20 As shown in FIG. 1 , the coil component 10d of this embodiment includes a second holding member 30 in addition to the first planar coil 11 and the first holding member 20. However, the structure of the first holding member 20 and the structure of the second holding member 30 are different from those of the first embodiment and the second embodiment. Fig.18 In the figure, for the convenience of explanation, the second holding member 30 is omitted.

[0452] Similar to the second embodiment, the second holding member 30 is integrated with the first planar coil 11 and the first holding member 20 in a manner that the first planar coil 11 is clamped with the first holding member 20. In addition, the second holding member 30 has magnetism. In detail, the second holding member 30 has magnetism and high resistance, preferably has insulation, but may not have magnetism. On the other hand, the second holding member 30 is different from the second embodiment in that the second planar coil 12 is buried. The second planar coil 12 is positioned in a manner that overlaps with the first planar coil 11. In the present embodiment, the first surface 12A, which is the opposite side of the second surface 12B of the second planar coil 12 that is opposite to the first planar coil 11, is exposed from the second holding member 30, but the first surface 12A may also be covered by the second holding member 30.

[0453] Similar to the first planar coil 11, the second planar coil 12 includes a plurality of turns 12n and a protruding piece 12T, the plurality of turns 12n are arranged in the radial direction of the second planar coil 12, and the protruding piece 12T extends from the inner periphery and / or the outer periphery of at least one of the plurality of turns 12n, and is bent in the axial direction in a manner away from the turns 12n of the second planar coil. Moreover, the protruding piece 12T of the second planar coil 12 is connected to the second holding member 30 in the radial direction. That is, the protruding piece 12T extends in a manner bent from the turns 12n toward the first holding member 20, and is embedded in the second holding member 30. Thus, the protruding piece 12T is connected to the second holding member 30 in the radial direction.

[0454] Specifically, the protruding piece 12T extends from the turn portion 12n toward the first holding member 20 and then extends away from the first holding member 20. The front end of the protruding piece 12T is flush or substantially flush with the first surface 12A of the turn portion 12n exposed to the outside.

[0455] In addition, in the present embodiment, the first holding member 20 further includes a protrusion 26 that protrudes from the groove 22 and is embedded in the second holding member 30. Moreover, the protrusion 26 faces the protruding piece 12T of the second planar coil 12 in the radial direction. In detail, the portion on the front end side of the protrusion 26 faces the portion on the front end side of the protruding piece 12T in the radial direction, and the portion on the front end side of the protruding piece 12T extends along the protrusion 26. In detail, the protrusion 26 extends in a manner protruding from the front end surface of the base portion 27 formed to bulge from the bottom surface 22A of the groove 22, specifically, from the central portion thereof. The base portion 27 protrudes to the middle position of the depth of the groove 22, specifically, the approximate midpoint, and extends between the radially opposite side surfaces 22B of the groove 22.

[0456] The second planar coil 12 is formed of a second coil intermediate material 12M (see FIG. 1 ) which is the same as the coil intermediate material 11M forming the first planar coil 11 and will be described later. Fig. 22 ) is formed. The second coil intermediate material 12M includes a connecting portion 12S that is the same as the connecting portion 11S of the coil intermediate material 11M. The protrusion 26 is a component for cutting the connecting portion 12S during the manufacturing process.

[0457] In addition, the first holding member 20 includes a spacer 28, which is provided in at least one of a portion between the slot 22 and the turn 11n radially inward relative to the slot 22 in the first surface 11A overlapping the first planar coil 11, and a portion between the slot 22 and the turn 11n radially outward relative to the slot 22. The spacer 28 protrudes away from the first planar coil 11. In the present embodiment, the spacer 28 is formed in both a portion between the slot 22 and the turn 11n radially inward relative to the slot 22 in the first surface 11A, and a portion between the slot 22 and the turn 11n radially outward relative to the slot.

[0458] The spacer 28 is formed at a position adjacent to the protrusion 26 in the radial direction. In addition, the protrusion piece 11T of the first planar coil 11 is not located at the portion where the spacer 28 is formed. The spacer 28 restricts the protrusion piece 12T from being bent in a manner close to the first planar coil 11. In addition, the spacer 28 is connected to the base portion 27 using a connecting portion 29 extending along the side surface 22B of the slot 22. In addition, the protrusion piece 11T of the first planar coil 11 and the protrusion piece 12T of the second planar coil 12 do not overlap each other but deviate in the circumferential direction.

[0459] In this embodiment, a space is formed between the protrusion 26 and the connection part 29 and between the base part 27 and the protruding piece 12T, and the space is filled with a part of the second holding member 30. The part of the second holding member 30 filled in the space is a part of the wall part 32.

[0460] The protrusion 26, the base 27 and the spacer 28 in the first holding member 20 described above can be Figure 7 and Figure 8 The convex portion 202 of the mold 200 shown is formed by forming a depression or a hole. That is, in this embodiment, the protrusion 26, the base 27 and the spacer 28 are integrally formed in the first holding member 20, but a jig including these protrusions 26, the base 27 and the spacer 28 may be formed and the jig may be inserted into the groove 22. In addition, the shape of the periphery of the protrusion 26 in the first holding member 20 may be changed in various ways, for example, the base 27 may not be present.

[0461] Below, refer to Figure 21 to Figure 25 An example of a method for manufacturing the coil component 10d will be described.

[0462] First, prepare Fig.21The preliminary coil part 10P shown. The preliminary coil part 10P is manufactured by the same manufacturing process as the coil part 10 of the first embodiment and has the same structure, but is different in that it has a protrusion 26, etc. In detail, the preliminary coil part 10P includes a first planar coil 11 and a first holding member 20. On the other hand, in the preliminary coil part 10P, the first holding member 20 includes a groove 22 on the first surface 11A overlapping the first planar coil 11, and the groove 22 is formed to be open between adjacent turns 11n. The first holding member 20 also includes a protrusion 26 protruding from the groove 22. The protrusion 26 protrudes from the groove 22 in a manner that passes over the first planar coil 11. Of course, the first holding member 20 includes a base 27 and a spacer 28.

[0463] In addition, if Fig. 22 As shown, a second coil intermediate material 12M is prepared and overlapped with the prepared coil part 10P. The second coil intermediate material 12M includes a plurality of turns 12n arranged in a radial direction and a connecting portion 12S connecting the radially adjacent turns 12n. Specifically, the second coil intermediate material 12M overlaps with the first planar coil 11 in the prepared coil part 10P in such a manner that the connecting portion 12S is opposite to the protrusion 26. It should be noted that in this embodiment, in more detail, as Fig.23 As shown, after the second molding material 230 is provided on the preliminary coil component 10P, the second coil intermediate material 12M is overlapped via the second molding material 230. In this example, the second molding material 230 is a liquid or sheet thermosetting resin before curing, but the second molding material 230 may also be a thermoplastic resin.

[0464] Then, if Fig.23 As shown, the opposing mold 240 is configured to face the second coil intermediate material 12M. The opposing mold 240 includes a plurality of cutting auxiliary protrusions 241 on the surface opposite to the second coil intermediate material 12M. In the present embodiment, the opposing mold 240 includes cutting auxiliary protrusions 241, and the number of the cutting auxiliary protrusions 241 is twice the number of the protrusions 26 in the first retaining member 20. The plurality of cutting auxiliary protrusions 241 include a plurality of pairs consisting of two cutting auxiliary protrusions 241 positioned close to each other, and the pairs of cutting auxiliary protrusions 241 are formed in a positional relationship in which the protrusions 26 can be accommodated therebetween when the opposing mold 240 approaches the prepared coil part 10P, and each cutting auxiliary protrusion 241 can enter the groove 22. It should be noted that in Fig.23 In the figure, for convenience of explanation, the portions corresponding to the protrusion 26, the base portion 27, and the spacer 28 are not shaded.

[0465] Furthermore, regarding the positional relationship between the opposing mold 240 and the preliminary coil component 10P, when viewed in the direction in which the opposing mold 240 and the preliminary coil component 10P overlap, the protrusion 26 is adjusted so that it is located between the pair of cutting auxiliary protrusions 241 and each cutting auxiliary protrusion 241 overlaps with the groove 22 and the connecting portion 12S. Fig.24 As shown, the cutting auxiliary protrusion 241 is pushed against the connecting portion 12S. As a result, the protrusion 26 is relatively pushed against the connecting portion 12S. At this time, the connecting portion 12S is separated from any one of the adjacent turns 12n connected, and is bent away from the turns 12n. As a result, the protruding piece 12T of the second planar coil 12 is formed by the connecting portion 12S.

[0466] At this time, in the present embodiment, the connection portion 12S is pressed toward the slot 22 by the cutting auxiliary protrusion 241, and on the other hand, the central side portion of the connection portion 12S cut off by the push of the protrusion 26 is bent in a direction away from the slot 22. Thus, the protruding piece 12T extends in a manner of bending from the turn portion 12n toward the first holding member 20, and then extends in a manner of bending away from the first holding member 20. In addition, when the connection portion 12S is pressed toward the slot 22 by the cutting auxiliary protrusion 241, the connection portion 12S is restricted from bending by the spacer 28, thereby avoiding a state where the connection portion 12S is too close to the first planar coil 11.

[0467] Then, the second molding material 230 is heated and solidified to form the second holding member 30. Fig.25 As shown, a coil component 10d is obtained.

[0468] In the coil component 10d of the fifth embodiment described above, the protruding piece 12T is in contact with the second holding member 30 in the radial direction. Thus, it is possible to suppress the second planar coil 12 from deviating from the second holding member 30, which is a member integrated with the second planar coil 12. In particular, in this embodiment, similarly to the protruding piece 11T of the first planar coil 11 described in the first embodiment, by forming the protruding piece 12T using the connecting portion 12S, which is a member that mainly performs its original function in the manufacturing process, the protruding piece 12T can be formed efficiently at low cost.

[0469] Although the embodiments of the present disclosure have been described above, various modifications may be made to the above-described embodiments. Such modifications may also be included in the technical scope of the present disclosure.

[0470] <<<Embodiment of the second disclosure>>>

[0471] Hereinafter, embodiments of the second disclosure will be described with reference to the drawings.

[0472] <<First embodiment of the second disclosure>>

[0473] <Coil parts>

[0474] Hereinafter, coil device 1010 according to the first embodiment will be described. Fig.26 It is a top view of coil device 1010 . Fig. 27 This is an exploded perspective view of coil component 1010 . Fig.28 10 is a cross-sectional view of coil device 1010 .

[0475] like Figure 26 to Figure 28 As shown, the coil device 1010 includes a first planar coil 1011 , a second planar coil 1012 , a first holding member 1020 , a second holding member 1030 , a first magnetic shield 1040 , a second magnetic shield 1050 , a first connection terminal 1061 , and a second connection terminal 1062 .

[0476] like Fig. 27 As shown, in the coil component 1010, the first planar coil 1011, the second planar coil 1012, the second holding member 1030, the first magnetic shielding member 1040 and the second magnetic shielding member 1050 are sequentially stacked on the first holding member 1020. Fig.26 In the figure, for the sake of convenience, the second holding member 1030, the first magnetic shielding member 1040 and the second magnetic shielding member 1050 are omitted, but in fact, the second holding member 1030, the first magnetic shielding member 1040 and the second magnetic shielding member 1050 overlap with the second planar coil 1012 represented by the solid line. Fig.26 In the figure, for the convenience of explanation, the first planar coil 1011 is indicated by a dotted line.

[0477] In addition, as described above, the second holding member 1030 overlaps with the second planar coil 1012. Fig. 27 In FIG. 1 , the second holding member 1030 is shown to be roughly arranged between the second planar coil 1012 and the first magnetic shielding member 1040. However, in reality, Fig.28 As shown, the second holding member 1030 has a portion interposed between the second planar coil 1012 and the first magnetic shielding member 1040, and another portion interposed between the first planar coil 1011 and the second planar coil 1012. The shape of the second holding member 1030 will be described in detail later. Fig.26 and Fig. 27 , the first connection terminal 1061 and the second connection terminal 1062 are simply indicated by two-dot chain lines. Hereinafter, each part of the coil device 1010 will be described in detail.

[0478] (First Planar Coil and Second Planar Coil)

[0479] The first planar coil 1011 is spiral-shaped and is made of a conductive material. In this embodiment, the first planar coil 1011 contains copper. Specifically, the first planar coil 1011 is made of copper. However, the first planar coil 1011 may also be made of a copper alloy, aluminum, an aluminum alloy, or the like.

[0480] like Fig. 27 As shown, the first planar coil 1011 is in the shape of a plate. Fig.28 As shown, the cross-sectional shape of the first planar coil 1011 in a direction orthogonal to the direction in which the first planar coil 1011 is wound in a spiral shape (in other words, the direction in which the first planar coil 1011 extends in a spiral shape) is a rectangular shape.

[0481] Fig.26 and Fig. 27 The reference symbol C1' shown in the figure represents the central axis of the first planar coil 1011 passing through the center of the spiral shape of the first planar coil 1011. Hereinafter, when the axial direction of the first planar coil 1011 is referred to, the direction refers to the direction extending on the first center axis C1' or the direction parallel to the first center axis C1'. In addition, the direction orthogonal to the first center axis C1' is referred to as the radial direction of the first planar coil 1011. The first planar coil 1011 includes a first surface 1011A and a second surface 1011B opposite to each other in the axial direction. The first planar coil 1011 overlaps the second planar coil 1012 on the first surface 1011A, and is opposite to the first holding member 1020 on the second surface 1011B.

[0482] like Fig. 27 As shown, the first planar coil 1011 has a conductor 1011E formed of a spiral shape by a plurality of turns 1011n. The plurality of turns 1011n of the first planar coil 1011 are arranged in a direction (radial direction) orthogonal to the first center axis C1' of the spiral shape. In detail, the plurality of turns 1011n are connected so as to gradually leave the first center axis C1' from the first center axis C1' of the spiral shape toward the radial direction outward. Then, a spiral shape is formed thereby.

[0483] The turn 1011n is basically a linear conductor portion that is not formed into a ring shape and is wound 360 degrees around the first center axis C1'. In the case of a so-called planar coil, the two ends of the turn 1011n deviate in the radial direction. Among the plurality of turns 1011n, the radially outer end of a certain turn 1011n is connected to the radially inner end of another turn 1011n, and the other turn 1011n extends away from the first center axis C1'.

[0484] Hereinafter, the turn portion closest to the first central axis C1' among the plurality of turns 1011n is sometimes referred to as the turn portion 10111. In addition, the turn portion connected to the turn portion 10111 is sometimes referred to as the turn portion 10112. In the present embodiment, the plurality of turns 1011n is composed of five turns 10111 to 10115. Hereinafter, when describing the common items in each of the plurality of turns 1011n, they are basically referred to as the turn portion 1011n.

[0485] In the present embodiment, the turn 1011n is wound in a manner to form a rectangular shape. However, the turn 1011n may also be wound in a manner to form a polygonal shape other than a rectangular shape. For example, the turn 1011n may also be wound in a manner to form an octagonal shape, a regular octagonal shape, a dodecagonal shape, or a regular dodecagonal shape. Furthermore, the turn 1011n may also be wound in a manner to form a circle. It should be noted that, as mentioned above, the vortex shape mentioned in this specification and the present disclosure refers to the shape of a plane curve wound in a spiral shape. The plane curve mentioned here also includes a plane pattern that is bent into a broken line shape as shown in the figure and is repeatedly wound. In addition, in other words, the vortex shape is a shape that is wound in a manner that gradually moves to the outside around the first center axis C1' of the first planar coil 1011.

[0486] The radially inner end (the end close to the first center axis C1') of the turn 111 closest to the first center axis C1' is electrically connected to the second planar coil 1012. On the other hand, the radially outer end (the end farthest from the first center axis C1') of the turn 10115 farthest from the first center axis C1' among the plurality of turns 1011n is connected to the first connection terminal 1061.

[0487] Here, the radial inner side of the first planar coil 1011 (turn 1011n) refers to the direction approaching the first center axis C1' in the radial direction. In addition, the radial outer side of the first planar coil 1011 (turn 1011n) refers to the direction away from the first center axis C1' in the radial direction. In addition, in the present embodiment, the first center axis C1' is determined as follows. First, from the radial inner end of the turn 10112 adjacent to the innermost turn 10111, linear imaginary turns of a shape similar to the turn 10112 are sequentially drawn in a manner to form a vortex shape in the radial inner side. Then, the drawing is continued until an imaginary turn contained within a diameter of 1 cm can be drawn. Then, a line passing through the radial inner area of ​​the imaginary turn contained within a diameter of 1 cm in a direction orthogonal to the circumferential and radial directions of the vortex shape is determined as the first center axis C1'.

[0488] As an example, the first planar coil 1011 of the present embodiment is formed by punching out a copper plate into a spiral shape. However, the first planar coil 1011 may be formed by etching a copper foil into a spiral shape.

[0489] The thickness of the first planar coil 1011 (the thickness of the conductor 1011E) may be, for example, greater than 0.1 mm and less than 1.0 mm. In addition, the radius of the first planar coil 1011 (the distance from the first center axis C1' to the portion farthest from the first center axis C1' in the radial direction) may be greater than 80 mm, or greater than 80 mm and less than 450 mm. In addition, the aspect ratio of the first planar coil 1011 (conductor 1011E) having a rectangular cross-sectional shape is determined by dividing the line width (radial width of each turn 1011n) of the first planar coil 1011 (conductor 1011E) by the thickness of the first planar coil 1011 (conductor 1011E). The aspect ratio of the first planar coil 1011 (conductor 1011E) may be less than 40, or greater than 2 and less than 12, or greater than 3 and less than 10.

[0490] In the case of transmitting power to an electric vehicle by magnetic field resonance, it is preferred that power of 1 kW or more, preferably 5 kW or more, can be transmitted in a frequency band of high-frequency current of preferably 10 kHz to 200 kHz, particularly 75 kHz or more and 100 kHz or less, and further 79 kHz to 90 kHz. In this case, the thickness of the first planar coil 1011 formed of copper is preferably 0.2 mm or more. From this point of view, the lower limit of the thickness of the first planar coil 1011 can also be set to 0.2 mm. In addition, in the case of transmitting power to an electric vehicle, it is not desirable to have an excessively large size, and sometimes the size is limited. From this point of view, the first planar coil 1011 and the second planar coil 1012 described later, in detail, the conductor 1011E of the first planar coil 1011 and the conductor 1012E of the second planar coil 1012 are also preferably formed in a size that is accommodated in a square with a side of 800 mm.

[0491] In addition, the line width of the first planar coil 1011 (the line width of the conductor 1011E), that is, the radial width (radial width) of each turn portion 1011n is not particularly limited. However, for example, when considering that an electric power of more than 1 kW, preferably more than 5 kW, can be transmitted in the frequency band of high-frequency current of 79 kHz to 90 kHz, the radial width of the turn portion 1011n can be more than 2 mm and less than 20 mm, or more than 2 mm and less than 16 mm, more than 2 mm and less than 12 mm, or more than 2 mm and less than 8 mm. In addition, the number of turns of the first planar coil 1011 can also be more than 4 and less than 12, but there is no particular limitation.

[0492] Next, the second planar coil 1012 is also in a spiral shape. In this embodiment, the second planar coil 1012 also contains copper. In detail, the second planar coil 1012 is formed of copper. It should be noted that the material of the second planar coil 1012 is not particularly limited, and can also be copper alloy, aluminum, aluminum alloy, etc. In addition, the second planar coil 1012 is also in a plate shape, such as Fig.28 As shown, the cross-sectional shape of the second planar coil 1012 in a direction perpendicular to the direction in which the second planar coil 1012 is wound in a spiral shape is a rectangular shape.

[0493] Fig.26 and Fig. 27 The reference symbol C2' shown in the figure represents the second center axis of the second planar coil 1012 passing through the center of the spiral shape of the second planar coil 1012. Hereinafter, when the axial direction of the second planar coil 1012 is referred to, the direction refers to the direction extending on the second center axis C2' or the direction parallel to the second center axis C2'. In addition, the direction orthogonal to the second center axis C2' is referred to as the radial direction of the second planar coil 1012. The second planar coil 1012 includes a first surface 1012A and a second surface 1012B opposite to each other in the axial direction. The second planar coil 1012 overlaps the second holding member 1030, the first magnetic shielding member 1040 and the second magnetic shielding member 1050 with the first surface 1012A, and is opposite to the first planar coil 1011 (first surface 1011A) on the second surface 1012B.

[0494] In this embodiment, the second planar coil 1012 is configured to be coaxial with the first planar coil 1011. That is, the first center axis C1' of the first planar coil 1011 and the second center axis C2' of the second planar coil 1012 are consistent, in other words, located on the same straight line. However, the first planar coil 1011 and the second planar coil 1012 may also overlap in a manner that the first center axis C1' of the first planar coil 1011 and the second center axis C2' of the second planar coil 1012 are parallel to each other. That is, the first planar coil 1011 and the second planar coil 1012 may not be coaxial.

[0495] The second planar coil 1012 also has a conductor 1012E formed of a plurality of turns 1012n in a spiral shape. The plurality of turns 1012n of the second planar coil 1012 are arranged in a direction orthogonal to the second central axis C2' of the spiral shape.

[0496] The connection method of the plurality of turns 1012n and the names corresponding to the positions (turns 10121, etc.) are the same as those of the turns 1011n of the first planar coil 1011. In the present embodiment, the number of turns of the first planar coil 1011 is the same as the number of turns of the second planar coil 1012, and the plurality of turns 1012n is composed of five turns 10121 to 10125. In addition, the turns 1012n are wound in a rectangular shape, similar to the turns 1011n. It should be noted that the turns 1012n may also be wound in a polygonal shape other than a rectangular shape. For example, the turns 1012n may also be wound in an octagonal shape, a regular octagonal shape, a dodecagonal shape, or a regular dodecagonal shape. Furthermore, the turns 1012n may also be wound in a circular shape. In addition, the number of turns of the first planar coil 1011 and the number of turns of the second planar coil 1012 may also be different. In addition, for example, the turn portion 1012n may be rectangular and the turn portion 1011n may be circular.

[0497] In addition, as described above, the radially inner end of the turn 10111 closest to the first center axis C1' is electrically connected to the second planar coil 1012. Specifically, the radially inner end of the turn 10111 is connected to the inner end of the turn 10121 in the second planar coil 1012. Here, when the first planar coil 1011 and the second planar coil 1012 are connected, the direction of winding from the end of the first planar coil 1011 not connected to the second planar coil 1012 (the radially outer end of the turn 10115) to the end connected to the second planar coil 1012 is the same as the direction of winding from the end of the second planar coil 1012 connected to the first planar coil 1011 to the end not connected to the first planar coil 1011 (the radially outer end of the turn 10125).

[0498] Moreover, the radially outer end of the turn 10125 farthest from the second center axis C2' among the multiple turns 1012n is connected to the second connection terminal 1062. It should be noted that the radial inner and outer directions of the second planar coil 1012 (turn 1012n) are determined in the same way as the radial inner and outer directions of the first planar coil 1011 described above. In addition, the method for determining the position of the second center axis C2' is also determined in the same way as the first center axis C1'. In addition, as an example, the second planar coil 1012 of the present embodiment is also formed by punching a copper plate into a spiral shape. However, the second planar coil 1012 can also be formed by etching a copper foil into a spiral shape.

[0499] In the present embodiment, the thickness of the second planar coil 1012 (the thickness of the conductor 1012E) may be, for example, not less than 0.1 mm and not more than 1.0 mm. In addition, the radius of the second planar coil 1012 (the distance from the second central axis C2' to the portion farthest from the second central axis C2' in the radial direction) may be not less than 80 mm, or not less than 80 mm and not more than 450 mm, as in the case of the first planar coil 1011. In addition, the aspect ratio of the second planar coil 1012 (conductor 1012E) whose cross-sectional shape is rectangular may be not more than 40, or not less than 2 and not more than 12, or not less than 3 and not more than 10, as in the case of the first planar coil 1011. In addition, the line width of the second planar coil 1012 (the line width of the conductor 1012E), that is, the radial width (radial width) of each turn portion 1012n may be not less than 2 mm and not more than 20 mm, or not less than 2 mm and not more than 16 mm, not less than 2 mm and not more than 12 mm, or not less than 2 mm and not more than 8 mm. In addition, the number of turns of the second planar coil 1012 may be greater than or equal to 4 and less than or equal to 12, but is not particularly limited.

[0500] In addition, the first planar coil 1011 and the second planar coil 1012 overlap with a gap therebetween. The gap may also be greater than 0.5 mm and less than 1.5 mm. There is no particular restriction on the size of the gap, but if the gap is too small, when current is supplied, there is a tendency for the eddy current loss generated in the first planar coil 1011 and the second planar coil 1012 to increase. In addition, if the gap is too large, the thinning of the coil component 1010 is damaged. As described above, the separation state of the first planar coil 1011 and the second planar coil 1012 is maintained by interposing the second retaining member 1030, which will be described later.

[0501] (First Holding Member)

[0502] The first holding member 1020 overlaps the first planar coil 1011 in a manner facing the second surface 1011B of the first planar coil 1011, and holds the first planar coil 1011. In the coil component 1010, for example, when power is transmitted, the magnetic field generated by the first planar coil 1011 and the second planar coil 1012 passes through the first holding member 1020. Therefore, in order not to hinder the magnetic field and in order not to generate eddy current, the first holding member 1020 is preferably non-conductive (insulating) and non-magnetic.

[0503] Considering that it is preferably non-conductive (insulating) and non-magnetic, the material of the first holding member 1020 is, for example, a resin, or a fiber-reinforced plastic. More specifically, the material of the first holding member 1020 may also be glass fiber reinforced polyamide. However, there is no particular limitation on the material of the first holding member 1020. For example, it may not contain glass fiber. In addition, thermoplastic resins or thermosetting resins other than polyamide may also be used. It should be noted that, as mentioned above, insulation refers to a volume resistivity of 10 10 Ω·m or more. Nonmagnetic means not showing magnetism.

[0504] The first holding member 1020 holds the first planar coil 1011 by being integrated with the first planar coil 1011. In the present embodiment, the first planar coil 1011 and the first holding member 1020, strictly speaking, their forming materials are hot stamped to integrate the first planar coil 1011 and the first holding member 1020. This integration is performed, for example, by the first holding member 1020 engaging with the concavo-convex surface of the first planar coil 1011 which is metal.

[0505] Here, the first planar coil 1011 and the first holding member 1020 are made of different materials, so there may be a situation where a strong adhesion cannot be obtained. Therefore, the first holding member 1020 of the present embodiment includes a base 1020B and a first rib 1021 and a second rib 1022 protruding from a contact surface 1020S, and the base 1020B includes a contact surface 1020S that is in contact with the second surface 1011B of the first planar coil 1011 and extends along the second surface 1011B. In addition, the first rib 1021 and the second rib 1022 can improve the stability of the integrated state of the first planar coil 1011 and the first holding member 1020.

[0506] Fig.29 1011 and 1020 are plan views of the first planar coil 1011 and the first holding member 1020 . Fig.30 It is along Fig.29 The cross-sectional view of the F30-F30 line, Fig.31 It is overlooking Fig.30 A perspective view of the cross section shown.

[0507] Fig.30 and Fig.31 A cross section of the first rib 1021 is shown. Fig.32 It is along Fig.30 The cross-sectional view of the F32-F32 line, Fig.33 It is along Fig.30 Cross-sectional view of the F33-F33 line. Fig.32 and Fig.33 A cross section of the second rib 1022 is shown.

[0508] like Figure 29 to Figure 31 As shown in FIG. 1 , a through hole 1011h is formed on the first planar coil 1011, which passes through from the first surface 1011A to the second surface 1011B. Fig.30 and Fig.31 As shown, the first rib 1021 is formed to pass through the through hole 1011 h formed in the first planar coil 1011 , and is in contact with or close to the inner circumferential surface of the through hole 1011 h in the radial direction of the first planar coil 1011 .

[0509] In detail, the first rib 1021 of the present embodiment includes: a first raised portion 1021A, which is in contact with or close to the through hole 1011h in the radial direction of the first planar coil 1011 and at the same time exceeds the first planar coil 1011 in the axial direction; and a first overhang portion 1021B, which extends from the first raised portion 1021A along the above-mentioned radial direction and is opposite to the first surface 1011A of the first planar coil 1011, and in detail, is in contact with the first surface 1011A of the first planar coil 1011.

[0510] When the first rib 1021 is formed, when the first planar coil 1011 is about to leave the first holding member 1020, the inner peripheral surface of the through hole 1011h contacts the first protrusion 1021A, thereby restricting the movement of the first planar coil 1011. In addition, the movement of the first planar coil 1011 can be more effectively restricted by the first surface 1011A contacting the first overhang 1021B.

[0511] It should be noted that the first rib 1021, in detail, the state in which the first raised portion 1021A is close to the inner circumferential surface of the through hole 1011h in the above-mentioned radial direction refers to a state in which the distance between the first raised portion 1021A and the through hole 1011h in the above-mentioned radial direction is less than 1 mm, preferably less than 0.5 mm, less than 0.2 mm, and the first raised portion 1021A passes through the through hole 1011h.

[0512] In this embodiment, refer to Fig.29 , a plurality of through holes 1011h are formed on the first planar coil 1011, and the plurality of through holes 1011h include a group of a plurality of through holes 1011h formed in each turn portion 1011n arranged side by side in the radial direction of the first planar coil 1011 and arranged side by side in the radial direction. Moreover, the first rib 1021 is formed in a manner passing through each through hole 1011h. That is, the first holding member 1020 includes a plurality of first ribs 1021, and the plurality of first ribs 1021 include a group of a plurality of first ribs 1021 arranged side by side at intervals in the radial direction of the first planar coil 1011.

[0513] In more detail, each turn 1011n in the first planar coil 1011 is a rectangular shape formed in a manner with rounded corners, and through holes 1011h are formed at the corners of the four rounded corners of each turn 1011n. Moreover, the first ribs 1021 are formed to be spaced apart and arranged side by side in the radial direction of the first planar coil 1011 on two diagonal lines of the first planar coil 1011. It should be noted that the formation position and number of the first ribs 1021 are not particularly limited, and can also be formed in a manner different from that of the present embodiment. For example, a plurality of first ribs 1021 can also be formed to be spaced apart and arranged side by side in a direction parallel to the radial direction of the first planar coil 1011.

[0514] In addition, Fig.30 A portion of the second planar coil 1012 is indicated by a double-dotted line. Fig.30 As shown, the second planar coil 1012 is arranged in a state of being connected to the first rib 1021. As described above, the first planar coil 1011 and the second planar coil 1012 overlap with a gap therebetween. Here, the first rib 1021 acts as a spacer for maintaining the gap between the first planar coil 1011 and the second planar coil 1012. The first planar coil 1011 and the second planar coil 1012 overlap with a gap therebetween, and the gap may also be greater than 0.5 mm and less than 1.5 mm. In this case, the thickness of the first overhang portion 1021B becomes greater than 0.5 mm and less than 1.5 mm. It should be noted that the first overhang portion 1021B may not be present in the first rib 1021.

[0515] Next, the second rib 1022 will be described. Fig.32 and Fig.33 As shown, the second rib 1022 is a portion protruding from the contact surface 1020S in the base portion 1020B of the first holding member 1020, and in contact with or close to the side surface of the first planar coil 1011 in the radial direction of the first planar coil 1011. Specifically, the second rib 1022 includes: a second raised portion 1022A, which is in contact with or close to the side surface of the first planar coil 1011 in the radial direction of the first planar coil 1011 and passes over the first planar coil 1011 in the axial direction; and a second overhang portion 1022B, which extends from the second raised portion 1022A in the above-mentioned radial direction, is opposite to the first surface 1011A, and specifically contacts the first surface 1011A (refer to Fig.33 It should be noted that the side surface of the first planar coil 1011 is a surface located between the first surface 1011A and the second surface 1011B.

[0516] When the second rib 1022 is formed, when the first planar coil 1011 is about to leave the first holding member 1020, the side surface of the first planar coil 1011 contacts the second raised portion 1022A, which may restrict the movement of the first planar coil 1011. In addition, the movement of the first planar coil 1011 can be more effectively restricted by the first surface 1011A contacting the second overhang portion 1022B.

[0517] The second raised portion 1022A of the present embodiment extends in a spiral shape along the spiral-shaped first planar coil 1011. In the present embodiment, the second raised portion 1022A extends continuously and uninterruptedly from the radial inner end to the outer end of the first planar coil 1011, but the second raised portion 1022A can also be formed intermittently in the direction in which the first planar coil 1011 extends in a spiral shape.

[0518] In addition, if Fig.32 and Fig.33 As shown, the side surface of the first planar coil 1011 includes an inner peripheral side surface 1013 in the side surface facing the first central axis C1' side in the radial direction of the first planar coil 1011, and an outer peripheral side surface 1014 located on the opposite side of the inner peripheral side surface 1013. In contrast, the second raised portion A in the second rib 1022 includes an inner raised portion 1022A1 in contact with or close to the inner peripheral side surface 1013 and an outer raised portion 1022A2 in contact with or close to the outer peripheral side surface 1014.

[0519] The inner raised portion 1022A1 and the outer raised portion 1022A2 protrude from the contact surface 1020S in a state of being separated in the radial direction of the first planar coil 1011. In more detail, the first retaining member 1020 forms a groove 1024 in a portion of the contact surface 1020S located between adjacent turns 1011n. The groove 1024 extends in a spiral shape along the spiral-shaped first planar coil 1011. Moreover, the inner raised portion 1022A1 and the outer raised portion 1022A2 adjacent in the radial direction of the first planar coil 1011 are separated in the above-mentioned radial direction in a state of interposing the turn 1011n therebetween, or are separated in the above-mentioned radial direction in a state of interposing the groove 1024. The groove 1024 is formed so that its bottom is deeper than the contact surface 1020S.

[0520] It should be noted that the state in which the second rib 1022, in detail, the second raised portion 1022A is close to the side surface of the first planar coil 1011 in the radial direction of the first planar coil 1011 refers to a state in which the distance between the second raised portion 1022A and the above-mentioned side surface in the above-mentioned radial direction is less than 1 mm, preferably less than 0.5 mm, less than 0.2 mm, and the second raised portion 1022A is adjacent to the above-mentioned side surface.

[0521] In addition, if Fig.33 As shown, the second rib 1022 includes a plurality of second overhanging portions 1022B extending from the second protruding portion 1022A along the radial direction of the first planar coil 1011. Fig.29 As shown, the plurality of second overhanging portions 1022B are arranged at intervals in the direction in which the first planar coil 1011 extends in a spiral shape. More specifically, the plurality of second overhanging portions 1022B include a plurality of groups of second overhanging portions 1022B, and the plurality of groups of second overhanging portions 1022B are arranged side by side at intervals in a direction parallel to the radial direction of the first planar coil 1011 and not passing through the first central axis C1'. Fig.29 In the example, there are 8.

[0522] That is, the second overhanging portion 1022B of the present embodiment partially covers the first surface 1011A of the first planar coil 1011. Although described later, the second holding member 1030 has magnetism and is formed in a state of partially contacting the first planar coil 1011. Here, the inventors of the present application have found that the larger the portion where the second holding member 1030 contacts the first planar coil 1011, the better the coil performance. Furthermore, the inventors of the present application have found that from the perspective of ensuring both good coil performance and good adhesion between the first planar coil 1011 and the first holding member 1020, the range where the second overhanging portion 1022B covers the first surface 1011A is preferably less than 25% of the area of ​​the first surface 1011A. The inventors of the present application have found through simulation that the Q value of the coil component 1010 when the second overhanging portion 1022B covers less than 25% of the area of ​​the first surface 1011A is only reduced by about 5% compared to the Q value when the second overhanging portion 1022B is not provided. It should be noted that, in consideration of adhesion, the range in which the second overhang portion 1022B covers the first surface 1011A may be greater than 5% of the area of ​​the first surface 1011A.

[0523] In the present embodiment, a group of a plurality of second overhang portions 1022B arranged side by side at intervals in a direction parallel to the radial direction of the first planar coil 1011 is provided avoiding the first rib 1021. Specifically, in the present embodiment, the two groups of a plurality of second overhang portions 1022B arranged side by side at intervals in a direction parallel to the radial direction of the first planar coil 1011 are located between the groups of a plurality of first ribs 1021 arranged side by side at intervals in the radial direction of the first planar coil 1011 that are adjacent in the circumferential direction. However, the formation position and number of the second overhang portions 1022B are not particularly limited, and the second overhang portions 1022B may be formed in a manner different from that of the present embodiment.

[0524] In addition, if Fig.33As shown, the second overhang portion 1022B is formed to cross the turn portion 1011n. That is, the second overhang portion 1022B spans the inner raised portion 1022A1 and the outer raised portion 1022A2 adjacent to each other with the turn portion 1011n interposed therebetween. However, the second overhang portion 1022B may also be formed so that the turn portion 1011n is partially open when observed in a radial cross section. In addition, the second overhang portion 1022B may also function as a spacer for maintaining the gap between the first planar coil 1011 and the second planar coil 1012. In this case, the thickness of the second overhang portion 1022B may also be greater than 0.5 mm and less than 1.5 mm.

[0525] (Second Holding Member)

[0526] return Fig.28 In this embodiment, the second holding member 1030 is integrated with the first planar coil 1011, the second planar coil 1012, and the first holding member 1020 in such a manner that the first planar coil 1011 and the second planar coil 1012 are clamped together with the first holding member 1020. As described above, the second holding member 1030 has a portion interposed between the second planar coil 1012 and the first magnetic shielding member 1040, and also has another portion interposed between the first planar coil 1011 and the second planar coil 1012.

[0527] Specifically, the second holding member 1030 includes a first layer portion 1031, a second layer portion 1032, a third layer portion 1033, a fourth layer portion 1034, and a fifth layer portion 1035 positioned so as to be stacked in a direction from the first magnetic shielding member 1040 toward the first holding member 1020. These first layer portion 1031, the second layer portion 1032, the third layer portion 1033, the fourth layer portion 1034, and the fifth layer portion 1035 are integrally formed without substantially any seams.

[0528] When viewed in the axial direction of the first planar coil 1011 and the second planar coil 1012 , the first layer portion 1031 , the second layer portion 1032 , the third layer portion 1033 , and the fourth layer portion 1034 are formed to have a size that includes the entirety of the first planar coil 1011 and the second planar coil 1012 .

[0529] The first layer portion 1031 is a sheet-like portion interposed between the second planar coil 1012 and the first magnetic shielding member 1040. The first layer portion 1031 is in contact with the first surface 1012A of the second planar coil 1012 and covers the first surface 1012A as a whole. The second layer portion 1032 is a portion overlapping the first layer portion 1031 and covering the side surface of the second planar coil 1012. In other words, the second layer portion 1032 is a portion that covers the entire side surface of the second planar coil 1012 from the inside and outside in the radial direction. It should be noted that the side surface of the second planar coil 1012 is a surface located between the first surface 1012A and the second surface 1012B.

[0530] The third layer portion 1033 is a portion interposed between the first planar coil 1011 and the second planar coil 1012. That is, the third layer portion 1033 is a portion that fills the gap between the first planar coil 1011 and the second planar coil 1012. In addition, the fourth layer portion 1034 is a portion that covers the side surface of the first planar coil 1011. In other words, the fourth layer portion 1034 is a portion that covers the entire side surface of the first planar coil 1011 from the inside and outside in the radial direction, and more precisely, covers it via the second rib 1022. Moreover, the surface of the fourth layer portion 1034 opposite to the surface connected to the third layer portion 1033 is flush with the second surface 1011B of the first planar coil 1011. Moreover, the fifth layer portion 1035 protrudes from the surface of the fourth layer portion 1034 that is flush with the second surface 1011B of the first planar coil 1011.

[0531] The fifth layer portion 1035 is filled in the groove 1024 in the first holding member 1020. Therefore, the fifth layer portion 1035 extends in a spiral shape along the first planar coil 1011 in a spiral shape.

[0532] The second holding member 1030 has magnetism as a whole, that is, the first layer 1031, the second layer 1032, the third layer 1033, the fourth layer 1034, and the fifth layer 1035 have magnetism respectively. The second holding member 1030 suppresses eddy current loss and leakage flux through magnetism, or improves the coupling coefficient, thereby achieving improved coil performance. The relative magnetic permeability of the second holding member 1030 is preferably greater than 2.0, and may be greater than 2.0 and less than 10.0. The relative magnetic permeability of the second holding member 1030 is more preferably greater than 5.0, and may be greater than 5.0 and less than 10.0. There is no particular restriction on the relative magnetic permeability of the second holding member 1030, but if it is too large, the flexibility or strength of the second holding member 1030 is sometimes undesirably damaged. Therefore, the relative magnetic permeability of the second holding member 1030 may also be less than 200.

[0533] In addition, by providing the fifth layer 1035 with the second holding member 1030, the coil performance can be effectively improved. The height of the fifth layer 1035 is not particularly limited, for example, it can be more than 0.5 mm, or it can be more than 1.0 mm. There is a tendency that the higher the height of the fifth layer 1035, the higher the effect of suppressing eddy current loss, and the higher the coupling coefficient. On the other hand, there is a tendency that the higher the fifth layer 1035, the easier it is to be damaged starting from the lower part. Therefore, the height of the fifth layer 1035, for example, can also be less than 10 mm. It should be noted that the fifth layer 1035 may not be provided.

[0534] As an example, the second holding member 1030 of this embodiment includes a resin and a plurality or countless magnetic particles made of a magnetic body. The magnetic particles are held in the resin as a holding material.

[0535] The magnetic particles can also be formed by any one or more of ferrite, particularly ferrite of soft magnetic material, nanocrystalline magnetic body, silicon steel, electromagnetic soft iron, and amorphous metal. The resin as the holding material can also be glass fiber reinforced polyamide. That is, the resin can also be formed by the material comprising polyamide and glass fiber as thermoplastic resin (thermoplastic material). However, the molding material of the second holding member 1030 is not particularly limited.

[0536] (First Magnetic Shielding Member)

[0537] The first magnetic shielding member 1040 is provided to suppress magnetic permeation and / or leakage magnetic field. The first magnetic shielding member 1040 is a sheet-shaped member that is separate from the first planar coil 1011, the second planar coil 1012, the first holding member 1020, and the second holding member 1030. The first magnetic shielding member 1040 is separate from the first planar coil 1011, the second planar coil 1012, the first holding member 1020, and the second holding member 1030, which means that the first magnetic shielding member 1040 is not integrated with these first planar coil 1011, the second planar coil 1012, the first holding member 1020, and the second holding member 1030. However, the first magnetic shielding member 1040 and the second holding member 1030 may also be joined via an adhesive layer or the like. The first magnetic shielding member 1040 is formed to include the first planar coil 1011, the second planar coil 1012, and the second holding member 1030 in a plan view. The first magnetic shielding member 1040 overlaps with the first planar coil 1011 , the second planar coil 1012 , and the second holding member 1030 , and is directly in contact with the second holding member 1030 .

[0538] The first magnetic shielding component 1040 of this embodiment has magnetism and contains a magnetic body or is composed of a magnetic body. In the coil component 1010, a magnetic field is generated when current is supplied to the first planar coil 1011 and the second planar coil 1012. The magnetic field generated in this coil component 1010 is generated in a manner that extends in all directions relative to the center axes C1' and C2' of the first planar coil 1011 and the second planar coil 1012. At this time, since the first magnetic shielding component 1040 has magnetism, the magnetic flux lines to be extended can be oriented toward the sides of the center axes C1' and C2'. In addition, the coil component 1010 can be set on the vehicle, but in this case, if the magnetic field generated in the coil component 1010 flows to the side of other vehicle parts, it sometimes has an adverse effect on the vehicle parts. In this case, the first magnetic shielding component 1040 can suppress the leakage magnetic field that does not contribute to the generation of current.

[0539] The first magnetic shielding member 1040 preferably includes a soft magnetic body or a nanocrystalline magnetic body. More specifically, the first magnetic shielding member 1040 includes ferrite, preferably a soft magnetic ferrite. In the present embodiment, the first magnetic shielding member 1040 includes a plate-shaped ferrite plate corresponding to the magnetic plate. More specifically, the first magnetic shielding member 1040 is formed by arranging a plurality of plate-shaped ferrite plates in a sheet shape.

[0540] The relative magnetic permeability of the first magnetic shielding member 1040 may be greater than or equal to 500, or greater than or equal to 1000. The relative magnetic permeability of the first magnetic shielding member 1040 may be greater than or equal to 500 and less than or equal to 3000, or greater than or equal to 1000 and less than or equal to 3000. It should be noted that, as mentioned above, the relative magnetic permeability in this specification is a value measured at a frequency of 85 kHz and an ambient temperature of 23 degrees.

[0541] (Second Magnetic Shielding Member)

[0542] The second magnetic shielding member 1050 is provided to cover the first magnetic shielding member 1040. In the present embodiment, the second magnetic shielding member 1050 is in contact with the first magnetic shielding member 1040, but instead of this, the second magnetic shielding member 1050 may be in contact with the first magnetic shielding member 1040 via a spacer. The second magnetic shielding member 1050 is formed of a metal material and has conductivity. Specifically, the second magnetic shielding member 1050 of the present embodiment is formed of aluminum. In this case, the magnetic flux is suppressed from leaking from the first planar coil 1011 and the second planar coil 1012 through the second magnetic shielding member 1050. It should be noted that the second magnetic shielding member 1050 may also be formed of an aluminum alloy, copper, stainless steel, etc.

[0543] (Connection terminal)

[0544] like Fig.26 and Fig. 27As shown, the first connection terminal 1061 is connected to the radially outer end of the turn portion 10115 in the first planar coil 1011. The second connection terminal 1062 is connected to the radially outer end of the turn portion 10125 in the second planar coil 1012. The first connection terminal 1061 and the second connection terminal 1062 can be used, for example, when connecting to the high-frequency current supply unit 1A or the conversion unit 2A. The connection between the first connection terminal 1061 and the turn portion 10115 and the connection between the second connection terminal 1062 and the turn portion 10125 can also be performed by ultrasonic bonding. However, there is no limitation on the connection method, and for example, a connection based on a conductive adhesive can also be used.

[0545] <Method for Manufacturing Coil Component 1010>

[0546] Next, an example of a method for manufacturing coil device 1010 will be described. Fig.34 This is a perspective view of a mold 1200 for manufacturing coil component 1010 . Fig.35 It is along Fig.34 Cross-sectional view of the F35-F35 line. Fig.36 It is along Fig.34 Cross-sectional view of the F36-F36 line. Fig.37 It is along Fig.34 Cross-sectional view of line F37-F37.

[0547] After the mold materials of the first planar coil 1011 and the first holding member 1020 are placed in sequence, the mold 1200 is connected to another mold 1210 (see Fig.38 ) are hot stamped between the first planar coil 1011 and the first holding member 1020. Thus, the first planar coil 1011 and the first holding member 1020 are integrated into a coil intermediate material 1010M (see Fig. 27 ).

[0548] The mold 1200 includes a plate-shaped main body 1201 having a flat installation surface 1200S on which the first planar coil 1011 is placed. The main body 1201 is provided with a convex portion 1202 that protrudes from the installation surface 1200S and extends in a spiral shape. Fig.28 The convex portion 1202 is a portion that forms the groove 1024 of the first holding member 1020. In addition, the first planar coil 1011 is provided in a spiral-shaped region of the contact surface 1020S extending along the spiral-shaped convex portion 1202.

[0549] In addition, if Fig.34As shown, a plurality of positioning protrusions 1203 are formed in the area where the first planar coil 1011 is set in the contact surface 1020S. The first planar coil 1011 has a hole for passing the positioning protrusions 1203. By passing the positioning protrusions 1203 through the holes of the first planar coil 1011, the first planar coil 1011 is positioned at a desired position. Figure 34 to Figure 37 A plurality of first recesses 1204 for forming the first overhanging portion 1021B in the first rib 1021 and a second recess 1205 for forming the second overhanging portion 1022B in the second rib 1022 are formed on the mold 1200 .

[0550] When the coil intermediate material 1010M is manufactured using the mold 1200 as described above, first, Fig.38 As shown, the first planar coil 1011 is set in the spiral-shaped area of ​​the setting surface 1200S of the main body 1201. The first planar coil 1011 is set in the mold 1200 in a state where the first surface 1011A is opposite to the setting surface 1200S. At this time, the first planar coil 1011 is positioned by passing a plurality of positioning protrusions 1203 through the holes of the first planar coil 1011. In addition, as shown in FIG. Fig.38 and Fig.39 As shown, radially adjacent portions of the convex portion 1202 receive the first planar coil 1011 in a state where a gap is provided relative to the side surface of the first planar coil 1011. That is, the distance between radially adjacent portions of the convex portion 1202 is greater than the width of the turn portion 1011n disposed therebetween. Furthermore, a forming material 1220 is provided above the first planar coil 1011. Then, the mold 1200 performs hot stamping on the first planar coil 1011 and the forming material 1220 between the mold 1200 and another mold 1210.

[0551] The hot stamping softens the molding material and turns it into a molten state, thereby forming the first holding member 1020 which includes the base portion 1020B, the first rib 1021 and the second rib 1022 and is integrated with the first planar coil 1011 .

[0552] In detail, Fig.38 and Fig.39 As shown, the second raised portion 1022A in the second rib 1022 is formed by filling a portion of the molding material 1220 into the gap between the radially adjacent portions of the convex portion 1202 and the turn portion 1011n. Fig.39As shown by the arrow α, a part of the molding material 1220 is filled into the second recess 1205. Then, the molding material 1220 is solidified in the second recess 1205, thereby forming the second overhanging portion 1022B in the second rib 1022. That is, the first planar coil 1011 is placed in the mold 1200 in a state of partially covering the second recess 1205, and the molding material 1220 is filled into the second recess 1205 from the portion of the second recess 1205 that is not covered by the second planar coil 1012. Thus, the second overhanging portion 1022B is formed.

[0553] In addition, if Fig.40 As shown in FIG. 1 , the first planar coil 1011 is placed in the mold 1200 in a state where the through hole 1011h formed in each turn portion 1011n overlaps with the second recess 1205. As a result, as shown by arrow β, a portion of the melted molding material 1220 passes through the through hole 1011h and fills the second recess 1205. Then, the molding material 1220 is solidified in the through hole 1011h and the second recess 1205 to form the first rib 1021. Then, the portion of the molding material 1220 remaining on the second surface 1011B of the first planar coil 1011 is solidified to form the base portion 1020B of the first holding member 1020.

[0554] As described above, the coil intermediate material 1010M is formed by integrating the first planar coil 1011 and the first holding member 1020. Then, the process of integrating the second planar coil 1012 and the second holding member 1030 with the coil intermediate material 1010M is performed to manufacture the coil part 1010. It should be noted that in the present embodiment, the forming material 1220 is melted between the molds 1200 and 1210 by hot stamping to form the coil intermediate material 1010M by integrating the first planar coil 1011 and the first holding member 1020. However, this manufacturing method is an example. For example, the coil intermediate material 1010M can also be formed by injecting the forming material between the molds 1200 and 1210.

[0555] <Applications of coil parts>

[0556] The coil component 1010 of the present embodiment can be used as a power transmission coil in the power transmission device 1 of the wireless power transmission system S described above, and can be used as a power reception coil in the power reception device 2 .

[0557] When the coil component 1010 is used as the power transmission coil, the first connection terminal 1061 and the second connection terminal 1062 are connected to Figure 1, or an AC power source as shown in . When a high-frequency current is supplied to the coil component 1010, the current can flow from the first connection terminal 1061 to the first planar coil 1011 and the second planar coil 1012, and then flow from the second connection terminal 1062 to the high-frequency current supply unit 1A or the AC power source. In addition, the current can flow from the second connection terminal 1062 to the second planar coil 1012 and the first planar coil 1011, and then flow from the first connection terminal 1061 to the high-frequency current supply unit 1A or the AC power source. Thus, a magnetic field including magnetic lines of force along the central axis of the planar coil can be generated.

[0558] On the other hand, when the coil component 1010 is used as a power receiving coil, a magnetic field including magnetic lines of force is received or generated by passing through the inside of the first planar coil 1011 and the second planar coil 1012, thereby enabling the first planar coil 1011 and the second planar coil 1012 to generate a high-frequency current. Furthermore, the high-frequency current can be supplied from the first connection terminal 1061 or the second connection terminal 1062 to an external device.

[0559] In addition, the coil component 1010 can also be used in a transformer, an antenna, etc. For example, when the coil component 1010 functions as a primary coil in a transformer, the first connection terminal 1061 and the second connection terminal 1062 are connected to an AC power source. In addition, by supplying a high-frequency current, a magnetic flux can be supplied from the center side of the planar coil to the iron core.

[0560] The coil device 1010 of the present embodiment described above includes a first planar coil 1011 having a spiral shape and including a first surface 1011A and a second surface 1011B extending on a first central axis C1' of the spiral shape and opposite to each other in the axial direction, and a first holding member 1020, wherein the first planar coil 1011 overlaps the first planar coil 1011 so as to face the second surface 1011B of the first planar coil 1011 and holds the first planar coil 1011. The first holding member 1020 includes a first rib 1021 and a second rib 1022. The first holding member 1020 includes a base 1020B, and the base 1020B includes a contact surface 1020S that is in contact with the second surface 1011B of the first planar coil 1011 and extends along the second surface 1011B, and the first rib 1021 and the second rib 1022 protrude from the contact surface 1020S.

[0561] Furthermore, the first rib 1021 includes a first protruding portion 1021A, which protrudes from the contact surface 1020S of the base portion 1020B and passes through the through hole 1011h formed in the first planar coil 1011, and is in contact with or close to the inner peripheral surface of the through hole 1011h in the radial direction of the first planar coil 1011. In addition, the second rib 1022 includes: a second protruding portion 1022A, which is in contact with or close to the side surface of the first planar coil 1011 in the radial direction of the first planar coil 1011 and passes over the first planar coil 1011 in the axial direction; and a second overhanging portion 1022B, which extends radially from the second protruding portion 1022A and is opposite to the first surface 1011A of the first planar coil 1011.

[0562] According to the coil device 1010 of this embodiment, when the first planar coil 1011 is about to leave the first holding member 1020, the inner peripheral surface of the through hole 1011h of the first planar coil 1011 contacts the first protrusion 1021A, and the movement of the first planar coil 1011 can be restricted. In addition, the first rib 1021 further includes a first overhanging portion 1021B, which extends radially from the first protrusion 1021A and faces the first surface 1011A of the first planar coil 1011. Therefore, when the first planar coil 1011 is about to leave the first holding member 1020, the first surface 1011A contacts the first overhanging portion 1021B, and the movement of the first planar coil 1011 can be more effectively restricted.

[0563] In addition, when the first planar coil 1011 is about to leave the first holding member 1020, the side surface of the first planar coil 1011 contacts the second protrusion 1022A, which may restrict the movement of the first planar coil 1011. Furthermore, the movement of the first planar coil 1011 can be more effectively restricted by the first surface 1011A contacting the second overhang 1022B.

[0564] Therefore, it is possible to suppress the first planar coil 1011 from floating up from the first holding member 1020 which is a sheet material integrated with the first planar coil 1011 .

[0565] <<Second embodiment of the second disclosure>>

[0566] Next, coil device 1010 ′ according to a second embodiment will be described. Fig.41 It is a partial cross-sectional view of coil device 1010 ′ according to the second embodiment. Fig.42 is a cross-sectional view of a mold 1200 ′ for manufacturing a coil component 1010 ′. Fig.431010 ′ is a diagram for explaining an example of a method for manufacturing a coil component 1010 ′. It should be noted that the same reference numerals are used for the components in the embodiments described below that are the same as or correspond to the first embodiment of the second disclosure. In the case of the same structure, the detailed description thereof is omitted.

[0567] exist Fig.41 1 shows the second rib 1022 of the coil component 1010' provided on the first holding member 1020. In the present embodiment, the second overhanging portion 1022B in the second rib 1022 is formed so that the turn portion 1011n is partially opened when viewed in a radial cross section. Specifically, the second overhanging portion 1022B includes: a first portion 1022B1, between which the turn portion 1011n is interposed and extending from the inner protrusion 1022A1 of the adjacent inner protrusion 1022A1 and the outer protrusion 1022A2; and a second portion 1022B2, which extends from the outer protrusion 1022A2.

[0568] Fig.42 Representation and Fig.36 The cross section shown corresponds to the cross section of the mold 1200'. In the mold 1200', the second recess 1205 is divided into an inner peripheral side recess 1205A forming the first portion 1022B1 of the second overhang portion 1022B, and an outer peripheral side recess 1205B forming the second portion 1022B2 of the second overhang portion 1022B. A portion of the contact surface 1020S where the first planar coil 1011 is disposed is located between the inner peripheral side recess 1205A and the outer peripheral side recess 1205B.

[0569] In the case where the first planar coil 1011 and the first holding member 1020 are integrated, as shown in FIG. Fig.43 As shown, the first planar coil 1011 is provided on the contact surface 1020S. At this time, the first planar coil 1011 is provided so that the inner periphery of the turn portion 1011n overlaps with the inner peripheral side recess 1205A, and the outer periphery of the turn portion 1011n overlaps with the outer peripheral side recess 1205B. Here, the inner peripheral side recess 1205A and the outer peripheral side recess 1205B are partially covered by the first planar coil 1011, and a part is opened to the outside. Thus, the molding material is filled from the open part into the inner peripheral side recess 1205A and the outer peripheral side recess 1205B, and the second rib 1022 having the second overhanging portion 1022B is formed, and the second overhanging portion 1022B includes the first portion 1022B1 and the second portion 1022B2.

[0570] Fig.44 1 is a cross-sectional view showing a modified example of the mold 1200'. Fig.44A support portion 1206 is provided in the mold, and the support portion 1206 is formed in a manner of being located inside the inner circumferential side recess 1205A and the outer circumferential side recess 1205B. In detail, the support portion 1206 includes a surface that protrudes from the bottom surface of the inner circumferential side recess 1205A and the outer circumferential side recess 1205B and is flush with the contact surface 1020S. In a modified example, when the first planar coil 1011 is placed on the mold in a manner such that the inner circumferential edge of the turn portion 1011n overlaps with the inner circumferential side recess 1205A, and the outer circumferential edge of the turn portion 1011n overlaps with the outer circumferential side recess 1205B, the portion near the outer circumferential edge of the turn portion 1011n and the portion near the inner circumferential edge are opposite to the support portion 1206. That is, the first planar coil 1011 is placed in the mold in such a manner that the portion of the first planar coil 1011 that covers the inner circumferential recess 1205A and the outer circumferential recess 1205B overlaps with the support portion 1206. Thus, when the molding material flows toward the inner circumferential recess 1205A and the outer circumferential recess 1205B, the turn portion 1011n is prevented from being deformed due to pressure. Thus, by preventing the molding material from narrowing its passage and hindering its flow, and preventing the first planar coil 1011 from being deformed, a suitable coil component 1010' can be stably obtained.

[0571] <<Third embodiment of the second disclosure>>

[0572] Next, a coil component 1010 ″ according to a third embodiment will be described. Fig.45 10 is a top view of a coil component 1010 ″ according to the third embodiment. Fig.46 It is along Fig.45 Cross-sectional view of the F46-F46 line. Fig.47 It is along Fig.45 Cross-sectional view of line F47-F47.

[0573] like Fig.45 As shown, the first magnetic shielding member 1040 of the present embodiment includes a plurality of plate-shaped ferrite plates 1041 corresponding to the magnetic plates. More specifically, the first magnetic shielding member 1040 is formed by arranging four ferrite plates 1041 in a sheet shape. It should be noted that, for the sake of convenience, the ferrite plates 1041 are indicated by double-dashed lines. Each ferrite plate 1041 is rectangular, and by arranging them in a full-covered manner, a rectangular first magnetic shielding member 1040 is formed.

[0574] In addition, in this embodiment, if Fig.46 and Fig.47As shown, the second planar coil 1012 is not provided, and the second holding member 1030 is provided in a manner covering the first planar coil 1011. Then, the first magnetic shielding member 1040 overlaps with the second holding member 1030. It should be noted that the second holding member 1030 may also be not provided, and the first magnetic shielding member 1040 may be provided in a manner in contact with the first planar coil 1011.

[0575] In addition, the formation position of the second overhanging portion 1022B of the second rib 1022 in the first holding member 1020 is different from that in the first embodiment. Fig.45 As shown, the plurality of second overhanging portions 1022B are arranged side by side at intervals in the radial direction of the first planar coil 1011. That is, the direction in which the plurality of second overhanging portions 1022B are arranged side by side passes through the first central axis C1' of the first planar coil 1011. Fig.47 As shown, the second overhanging portion 1022B in the second rib 1022 is not covered by the second holding member 1030 but protrudes from the second holding member 1030. The size (thickness) of the second overhanging portion 1022B protruding from the second holding member 1030 may also be greater than or equal to 1.5 mm and less than or equal to 5 mm.

[0576] In the example shown in the figure, one surface of the second overhang 1022B facing the second magnetic shield 1050 is flush with one surface of the first magnetic shield 1040. In this case, the second magnetic shield 1050 is installed in contact with the second overhang 1022B and the first magnetic shield 1040, so the installation state is stable.

[0577] Furthermore, the plurality of ferrite plates 1041 overlap with the second holding member 1030 in a manner avoiding the second overhanging portion 1022B protruding from the second holding member 1030. Fig.45 As shown, the two ferrite plates 1041 are configured to clamp a plurality of second overhang portions 1022B, and the plurality of second overhang portions 1022B are arranged side by side with intervals in the radial direction of the first planar coil 1011. In the present embodiment, the two ferrite plates 1041 are connected to the plurality of second overhang portions 1022B. In the illustrated example, the group of second overhang portions 1022B arranged side by side with intervals in the radial direction of the first planar coil 1011 is located on one side and the other side of the first center axis C1'. Moreover, the pair of two ferrite plates 1041 clamping the plurality of second overhang portions 1022B arranged side by side with intervals in the radial direction of the first planar coil 1011 is located on one side and the other side of the first center axis C1'. In addition, two adjacent ferrite plates 1041 that do not clamp the plurality of second overhang portions 1022B are connected to each other.

[0578] In the above-described embodiment, when it is preferable to provide a gap between adjacent ferrite plates 1041 , the ferrite plates 1041 can be arranged in a desired state using the second overhanging portion 1022B.

[0579] <<Another embodiment of the second disclosure>>

[0580] Fig.48 It is a cross-sectional view of a coil component according to another embodiment. Fig.48 The coil component shown also includes an adhesive layer 1026 containing a thermoplastic resin, which bonds the second surface 1011B of the first planar coil 1011 to the contact surface 1020S of the first holding member 1020. The thermoplastic resin contained in the adhesive layer 1026 may be polyethylene, specifically, low-density polyethylene, medium-density polyethylene, high-density polyethylene, etc., but there is no particular limitation.

[0581] The adhesive layer 1026 may also be formed of a heat-sealing film, for example. In this case, the heating sheet film melted by heating is solidified by cooling, thereby forming the adhesive layer 1026. In this case, the heating sheet film is attached to the first planar coil 1011, and the molding material forming the first retaining member 1020 is placed on the heat-sealing film and hot stamping is performed, thereby heating the heat-sealing film. In this hot stamping, the heat-sealing film is preferably melted between 140°C and 160°C. From this point of view, the above-mentioned thermoplastic resin may also be polyethylene whose melting point is generally about 120°C.

[0582] According to the above Fig.48 In the illustrated embodiment, the adhesion between the first planar coil 1011 and the first holding member 1020 can be improved.

[0583] Fig.49 FIG. 1 is a cross-sectional view of a coil component according to another embodiment. Fig.49 In the coil parts shown, the surface roughness of the second surface 1011B of the first planar coil 1011 is greater than the surface roughness of the first surface 1011A. As a result, the closeness between the first planar coil 1011 and the first holding member 1020 can be improved. It should be noted that the surface roughness of the first surface 1011A and the surface roughness of the second surface 1011B can be the same. The surface roughness mentioned here is the arithmetic mean roughness defined by JIS B0601 (2013). The first surface 1011A can also be adjusted to the desired surface roughness by roughening treatment such as etching.

[0584] Although the embodiments of the present disclosure have been described above, various modifications may be made to the above-described embodiments. Such modifications may also be included in the technical scope of the present disclosure.

[0585] <<<Third disclosed embodiment>>>

[0586] Hereinafter, embodiments of the third disclosure will be described with reference to the drawings.

[0587] <Coil parts>

[0588] Hereinafter, coil component 2010 according to one embodiment will be described. Fig.50 It is a top view of coil component 2010 . Fig.51 This is an exploded perspective view of the coil component 2010 . Fig.52 It is a cross-sectional view of the coil component 2010 along the central axes C1 ″ and C2 ″ of the planar coils 2011 and 2012 described later.

[0589] like Figure 50 to Figure 52 As shown, the coil device 2010 includes a first planar coil 2011 , a second planar coil 2012 , a first holding member 2020 , a second holding member 2030 , a first magnetic shield 2040 , a second magnetic shield 2050 , a first connection terminal 2061 , and a second connection terminal 2062 .

[0590] like Fig.51 As shown, in the coil component 2010, the first planar coil 2011, the second planar coil 2012, the second holding member 2030, the first magnetic shielding member 2040, and the second magnetic shielding member 2050 are sequentially stacked on the first holding member 2020. Fig.50 In the figure, for the sake of convenience, the second holding member 2030, the first magnetic shielding member 2040 and the second magnetic shielding member 2050 are omitted, but in fact, the second holding member 2030, the first magnetic shielding member 2040 and the second magnetic shielding member 2050 overlap with the second planar coil 2012 indicated by the solid line. Fig.50 In FIG. 2 , for the convenience of explanation, the first planar coil 2011 is indicated by a dotted line. Fig.50 and Fig.51 In FIG. 2 , first connection terminal 2061 and second connection terminal 2062 are simply indicated by two-dot chain lines. Hereinafter, each part of coil device 2010 will be described in detail.

[0591] (First Planar Coil and Second Planar Coil)

[0592] The first planar coil 2011 is spiral-shaped and is made of a conductive material. In this embodiment, the first planar coil 2011 contains copper. Specifically, the first planar coil 2011 is made of copper. However, the first planar coil 2011 may also be made of a copper alloy, aluminum, an aluminum alloy, or the like.

[0593] like Fig.51As shown, the first planar coil 2011 is in the shape of a plate. Fig.52 As shown, the cross-sectional shape of the first planar coil 2011 in a direction perpendicular to the direction in which the first planar coil 2011 is wound in a spiral shape, in other words, the direction in which the first planar coil 2011 extends in a spiral shape, is a rectangular shape.

[0594] Figure 50 to Figure 52 The reference symbol C1" shown in the figure represents the first center axis of the first planar coil 2011 passing through the center of the spiral shape of the first planar coil 2011. Hereinafter, when the axial direction of the first planar coil 2011 is referred to, the direction refers to the direction extending on the first center axis C1" or the direction parallel to the first center axis C1". In addition, the radial direction of a circle drawn on a plane orthogonal to the first center axis C1" with an arbitrary point on the first center axis C1" as the center is referred to as the radial direction of the first planar coil 2011. The first planar coil 2011 includes a first surface 2011A and a second surface 2011B which are opposite to each other in the axial direction. The first planar coil 2011 overlaps the second planar coil 2012 on the first surface 2011A, and is opposite to the first retaining member 2020 on the second surface 2011B.

[0595] like Fig.51 As shown, the first planar coil 2011 has a conductor 2011E formed of a spiral shape by a plurality of turns 2011n. The plurality of turns 2011n of the first planar coil 2011 are arranged in a direction orthogonal to the first center axis C1" of the spiral shape. Specifically, the plurality of turns 2011n are connected so as to gradually move away from the first center axis C1" of the spiral shape toward the radially outer side of the first planar coil 2011, thereby forming a spiral shape.

[0596] The turn 2011n is basically a linear conductor portion that is not in a ring shape and is wound 360 degrees around the first center axis C1". In the case of a so-called planar coil, the two ends of the turn 2011n are deviated in the radial direction of the first planar coil 2011. Among the multiple turns 2011n, the radial outer end of a certain turn 2011n is connected to the radial inner end of another turn 2011n, and the other turn 2011n extends in a manner away from the first center axis C1".

[0597] In the following, the turn portion closest to the first center axis C1" among the multiple turns 2011n is sometimes referred to as the turn portion 20111. In addition, the turn portion connected to the turn portion 20111 is sometimes referred to as the turn portion 20112. In the present embodiment, the multiple turns 2011n include five turns 20111 to 20115. In the following, when describing the common matters in each of the multiple turns 2011n, they are basically referred to as the turn portion 2011n.

[0598] In the present embodiment, the turn 2011n is wound in a manner to form a rectangular shape. However, the turn 2011n may be wound in a manner to form a polygonal shape other than a rectangular shape. For example, the turn 2011n may be wound in a manner to form an octagonal shape, a regular octagonal shape, a dodecagonal shape, or a regular dodecagonal shape. Furthermore, the turn 2011n may be wound in a manner to form a circle. It should be noted that, as mentioned above, the vortex shape mentioned in this specification and the present disclosure refers to the shape of a plane curve wound into a spiral shape. The plane curve mentioned here also includes a plane pattern that is bent into a broken line shape as shown in the figure and is repeatedly wound. In addition, in other words, the vortex shape refers to the shape of a plane curve that moves away from the center as it turns (or approaches the center as it turns).

[0599] The radially inner end (the end close to the first center axis C1”) of the turn 20111 closest to the first center axis C1” is electrically connected to the second planar coil 2012. On the other hand, the radially outer end (the end away from the first center axis C1”) of the turn 20115 farthest from the first center axis C1” among the multiple turns 2011n is connected to the first connecting terminal 2061.

[0600] Here, the radial inner side of the first planar coil 2011 (turn 2011n) refers to the direction approaching the first center axis C1" in the radial direction. In addition, the radial outer side of the first planar coil 2011 (turn 2011n) refers to the direction away from the first center axis C1" in the radial direction. In addition, in the present embodiment, the first center axis C1" is determined as follows. First, from the radial inner end of the turn 20112 adjacent to the innermost turn 20111, linear imaginary turns of a shape similar to the turn 20112 are sequentially drawn in a manner to form a spiral shape in the radial inner side. Then, the drawing is continued until an imaginary turn contained within a diameter of 1 cm can be drawn. Then, a line passing through the radial inner area of ​​the imaginary turn contained within a diameter of 1 cm in a direction orthogonal to the circumferential and radial directions of the spiral shape is determined as the first center axis C1".

[0601] As an example, the first planar coil 2011 of the present embodiment is formed by punching out a copper plate into a spiral shape. However, the first planar coil 2011 may be formed by etching a copper foil into a spiral shape.

[0602] The thickness of the first planar coil 2011 (the thickness of the conductor 2011E) may be, for example, greater than 0.1 mm and less than 1.0 mm. In addition, the radius of the first planar coil 2011 (the distance from the first center axis C1″ to the portion radially farthest from the first center axis C1″) may be greater than 80 mm, or greater than 80 mm and less than 450 mm. In addition, the aspect ratio of the first planar coil 2011 (conductor 2011E) having a rectangular cross-sectional shape is determined by dividing the line width (radial width of each turn 2011n) of the first planar coil 2011 (conductor 2011E) by the thickness of the first planar coil 2011 (conductor 2011E). The aspect ratio of the first planar coil 2011 (conductor 2011E) may be greater than 2 and less than 12, or greater than 3 and less than 10.

[0603] In the case of transmitting power to an electric vehicle by magnetic field resonance, it is preferred that power of 1 kW or more, preferably 5 kW or more, can be transmitted in a frequency band of high-frequency current of 10 kHz to 200 kHz, particularly 75 kHz or more and 100 kHz or less, and further 79 kHz to 90 kHz. In this case, the thickness of the first planar coil 2011 formed of copper is preferably 0.2 mm or more. From this point of view, the lower limit of the thickness of the first planar coil 2011 can also be set to 0.2 mm. In addition, in the case of transmitting power to an electric vehicle, it is not desirable to have an excessively large size, and sometimes the size is limited. From this point of view, the first planar coil 2011 and the second planar coil 2012 described later, in detail, the conductor 2011E of the first planar coil 2011 and the conductor 2012E of the second planar coil 2012 are also preferably formed in a size that is accommodated in a square with a side of 800 mm.

[0604] In addition, the line width of the first planar coil 2011 (the line width of the conductor 2011E), that is, the radial width (radial width) of each turn portion 2011n is not particularly limited. However, for example, when considering that an electric power of more than 1 kW, preferably more than 5 kW, can be transmitted in the frequency band of high-frequency current of 79 kHz to 90 kHz, the radial width of the turn portion 2011n can be more than 2 mm and less than 20 mm, or more than 2 mm and less than 16 mm, more than 2 mm and less than 12 mm, or more than 2 mm and less than 8 mm. In addition, the number of turns of the first planar coil 2011 can also be more than 4 and less than 12, but there is no particular limitation.

[0605] Next, the second planar coil 2012 is also in a spiral shape. In this embodiment, the second planar coil 2012 also contains copper. In detail, the second planar coil 2012 is formed of copper. It should be noted that the material of the second planar coil 2012 is not particularly limited, and can also be copper alloy, aluminum, aluminum alloy, etc. In addition, the second planar coil 2012 is also in a plate shape, such as Fig.52 As shown, the cross-sectional shape of the second planar coil 2012 in a direction perpendicular to the direction in which the second planar coil 2012 is wound in a spiral shape is a rectangular shape.

[0606] Figure 50 to Figure 52 The reference symbol C2" shown in the figure represents the second central axis of the second planar coil 2012 passing through the center of the spiral shape of the second planar coil 2012. Hereinafter, when the axial direction of the second planar coil 2012 is referred to, the direction is a direction extending on the second central axis C2" or a direction parallel to the second central axis C2". In addition, the radial direction of a circle drawn on a plane orthogonal to the second central axis C2" with an arbitrary point on the second central axis C2" as the center is referred to as the radial direction of the second planar coil 2012. The second planar coil 2012 includes a first surface 2012A and a second surface 2012B opposite to each other in the axial direction. The second planar coil 2012 overlaps the second holding component 2030, the first magnetic shielding component 2040 and the second magnetic shielding component 2050 on the first surface 2012A, and faces the first planar coil 2011 (first surface 2011A) on the second surface 2012B.

[0607] In the present embodiment, the second planar coil 2012 is configured to be coaxial with the first planar coil 2011. That is, the first center axis C1” of the first planar coil 2011 and the second center axis C2” of the second planar coil 2012 are consistent, in other words, located on the same straight line. However, the first planar coil 2011 and the second planar coil 2012 may overlap in such a manner that the first center axis C1” of the first planar coil 2011 and the second center axis C2” of the second planar coil 2012 are parallel to each other. That is, the first planar coil 2011 and the second planar coil 2012 may not be coaxial.

[0608] The second planar coil 2012 also has a conductor 2012E formed of a plurality of turns 2012n in a spiral shape. The plurality of turns 2012n of the second planar coil 2012 are arranged in a direction orthogonal to the second central axis C2″ of the spiral shape.

[0609] The connection method of the plurality of turns 2012n and the names corresponding to the positions (turns 20121, etc.) are the same as the turns 2011n of the first planar coil 2011. In the present embodiment, the number of turns of the first planar coil 2011 is the same as the number of turns of the second planar coil 2012, and the plurality of turns 2012n includes five turns 20121 to 20125. In addition, the turns 2012n are wound in a rectangular shape, the same as the turns 2011n. It should be noted that the turns 2012n may also be wound in a polygonal shape other than a rectangular shape. For example, the turns 2012n may also be wound in an octagonal shape, a regular octagonal shape, a dodecagonal shape, or a regular dodecagonal shape. Furthermore, the turns 2012n may also be wound in a circular shape. In addition, the number of turns of the first planar coil 2011 and the number of turns of the second planar coil 2012 may also be different. In addition, for example, the turn portion 2012n may be rectangular and the turn portion 2011n may be circular.

[0610] In addition, as described above, the radially inner end of the turn 20111 closest to the first center axis C1" is electrically connected to the second planar coil 2012. Specifically, the radially inner end of the turn 20111 is connected to the radially inner end of the turn 20121 in the second planar coil 2012. Here, when the first planar coil 2011 and the second planar coil 2012 are connected, the direction of winding from the end of the first planar coil 2011 that is not connected to the second planar coil 2012 (the radially outer end of the turn 20115) to the end connected to the second planar coil 2012 is the same as the direction of winding the second planar coil 2012 from the end connected to the first planar coil 2011 to the end not connected to the first planar coil 2011 (the radially outer end of the turn 20125).

[0611] Then, the radially outer end of the turn 20125 farthest from the second center axis C2" among the multiple turns 2012n is connected to the second connecting terminal 2062. It should be noted that the directions represented by the radial inner and outer directions of the second planar coil 2012 (turn 2012n) are determined in the same way as the radial inner and outer directions of the above-mentioned first planar coil 2011. In addition, the method for determining the position of the second center axis C2" is also determined in the same way as the case of the first center axis C1". In addition, as an example, the second planar coil 2012 of this embodiment is also formed by punching a copper plate into a spiral shape. However, the second planar coil 2012 can also be formed by etching a copper foil into a spiral shape.

[0612] In the present embodiment, the thickness of the second planar coil 2012 (the thickness of the conductor 2012E) may be, for example, greater than 0.1 mm and less than 1.0 mm. In addition, the radius of the second planar coil 2012 (the distance from the second center axis C2" to the portion farthest from the second center axis C2" in the radial direction) may be greater than 80 mm, or greater than 80 mm and less than 450 mm, as in the case of the first planar coil 2011. In addition, the aspect ratio of the second planar coil 2012 (conductor 2012E) having a rectangular cross-sectional shape may be greater than 2 and less than 12, or greater than 3 and less than 10, as in the case of the first planar coil 2011. In addition, the line width of the second planar coil 2012 (the line width of the conductor 2012E), that is, the radial width (radial width) of each turn 2012n may be greater than 2 mm and less than 20 mm, or may be greater than 2 mm and less than 16 mm, greater than 2 mm and less than 12 mm, or greater than 2 mm and less than 8 mm. In addition, the number of turns of the second planar coil 2012 may be greater than or equal to 4 and less than or equal to 12, but is not particularly limited.

[0613] In addition, if Fig.52 As shown, the first planar coil 2011 and the second planar coil 2012 overlap with a gap in their axial direction. The gap can also be greater than 0.5 mm and less than 1.5 mm. There is no particular restriction on the size of the gap, but if the gap is too small, when current is supplied, there is a tendency for the eddy current loss generated in the first planar coil 2011 and the second planar coil 2012 to change. In addition, if the gap is too large, the thinning of the coil part 2010 is damaged. The gap between the first planar coil 2011 and the second planar coil 2012 is maintained by interposing a second retaining member 2030 between the planar coils 2011 and 2012 as described later.

[0614] (First Holding Member)

[0615] The first holding member 2020 overlaps the first planar coil 2011 in a manner facing the second surface 2011B of the first planar coil 2011, and holds the first planar coil 2011. In the coil component 2010, for example, when power is transmitted, the magnetic field generated in the first planar coil 2011 and the second planar coil 2012 passes through the first holding member 2020. Therefore, in order not to hinder the magnetic field and in order not to generate eddy current, the first holding member 2020 is preferably non-conductive (insulating) and non-magnetic.

[0616] Considering that it is preferably non-conductive (insulating) and non-magnetic, the material of the first holding member 2020 is, for example, a resin, or a fiber-reinforced plastic. More specifically, the material of the first holding member 2020 may also be glass fiber reinforced polyamide. However, there is no particular limitation on the material of the first holding member 2020. For example, it may not contain glass fiber. In addition, thermoplastic resins or thermosetting resins other than polyamide may also be used. It should be noted that, as mentioned above, insulation refers to a volume resistivity of 10 10 Ω·m or more. Nonmagnetic means not showing magnetism.

[0617] The first holding member 2020 is integrated with the first planar coil 2011 to hold the first planar coil 2011. In this embodiment, a mold 2200 (see Fig.56 ), the material for making the first holding member is pressed into the above-mentioned mold 2200 by hot stamping to be formed, and the material is cooled to solidify, thereby integrating the first planar coil 2011 and the first holding member 2020. In this specification, the parts that integrate the first holding member 2020 and the first planar coil 2011 are all referred to as coil intermediate materials 2010M.

[0618] In this embodiment, the first holding member 2020 and the second holding member 2030 clamp the first planar coil 2011 and the second planar coil 2012. The first holding member 2020 has a contact surface 2020S1 that contacts the second surface 2011B of the first planar coil 2011. The contact surface 2020S1 forms the inner surface of the first holding member 2020. In addition, the first holding member 2020 has an outer surface 2020S2 on the opposite side of the contact surface 2020S1.

[0619] like Fig.52 and Fig.53 As shown in FIG. 2 , a first groove 2024 is formed on the contact surface 2020S1 to accommodate a protrusion 2032 of a second holding member 2030 described later. Fig.52 and Fig.54 As shown, the outer surface 2020S2 is formed with a second groove 2025. The first groove 2024 and the second groove 2025 will be described in detail later.

[0620] (Second Holding Member)

[0621] like Fig.52As shown, the second holding member 2030 of this embodiment is integrated with the first planar coil 2011, the second planar coil 2012 and the first holding member 2020 in such a manner as to clamp the first planar coil 2011 and the second planar coil 2012 with the first holding member 2020. As described above, the second holding member 2030 has a part interposed between the second planar coil 2012 and the first magnetic shielding member 2040, and also has another part interposed between the first planar coil 2011 and the second planar coil 2012.

[0622] In detail, the second holding member 2030 includes a base 2031 interposed between the second planar coil 2012 and the first magnetic shielding member 2040, and a protrusion 2032 protruding from the base 2031 toward the first holding member 2020. The base 2031 entirely covers the first surface 2012A of the second planar coil 2012. When viewed in the axial direction of the first planar coil 2011 and the second planar coil 2012, the base 2031 is formed to have a size that includes the entirety of the first planar coil 2011 and the second planar coil 2012. The base 2031 and the first holding member 2020 sandwich the first planar coil 2011 and the second planar coil 2012 therebetween.

[0623] The protrusion 2032 extends along the axial direction of the first planar coil 2011 between adjacent turns of the first planar coil 2011. Therefore, the protrusion 2032 is formed along the spiral-shaped first planar coil 2011. In the illustrated example, the protrusion 2032 is formed into a spiral shape corresponding to the spiral shape of the first planar coil 2011. As described above, the protrusion 2032 is accommodated in the first groove 2024 of the first retaining member 2020. In other words, the protrusion 2032 is filled in the first groove 2024 of the first retaining member 2020.

[0624] In the example shown in the figure, the second holding member 2030 further includes a spacer 2033 disposed between the first planar coil 2011 and the second planar coil 2012. The spacer 2033 maintains a gap between the first planar coil 2011 and the second planar coil 2012. In other words, the second planar coil 2012 is embedded in the second holding member 2030. The portion of the second holding member 2030 that covers the second surface 2012B of the second planar coil 2012 is the spacer 2033. The spacer 2033 is in contact with the first surface 2011A of the first planar coil 2011.

[0625] The second holding member 2030 has magnetism as a whole, that is, the base 2031, the protrusion 2032 and the spacer 2033 have magnetism respectively. The second holding member 2030 suppresses eddy current loss and leakage flux through magnetism, or improves the coupling coefficient, thereby achieving improved coil performance. The relative magnetic permeability of the second holding member 2030 is preferably greater than 2.0, and may be greater than 2.0 and less than 10.0. The relative magnetic permeability of the second holding member 2030 is more preferably greater than 5.0, and may be greater than 5.0 and less than 10.0. There is no particular restriction on the relative magnetic permeability of the second holding member 2030, but if it is too large, the flexibility or strength of the second holding member 2030 is sometimes unexpectedly damaged. Therefore, the relative magnetic permeability of the second holding member 2030 may also be less than 200.

[0626] In addition, the second holding member 2030 can effectively improve the coil performance by having a protrusion 2032. The height of the protrusion 2032 (the distance between the top of the protrusion 2032 and the second surface 2011B of the first planar coil 2011 along the axial direction of the first planar coil 2011) is not particularly limited, and can be, for example, more than 0.5 mm, or more than 1.0 mm. There is a tendency that the higher the height of the protrusion 2032, the higher the effect of suppressing eddy current loss and the more the coupling coefficient is improved. On the other hand, there is a tendency that the higher the protrusion 2032, the easier it is to be damaged starting from the lower part. Therefore, the height of the protrusion 2032 can also be, for example, less than 10 mm.

[0627] As an example, the second holding member 2030 of this embodiment includes a resin and a plurality or countless magnetic particles made of a magnetic body. The magnetic particles are held in the resin as a holding material.

[0628] The magnetic particles can also be formed by any one or more of ferrite, particularly ferrite of soft magnetic material, nanocrystalline magnetic body, silicon steel, electromagnetic soft iron, and amorphous metal. The resin as the holding material can also be glass fiber reinforced polyamide. That is, the resin can also be formed by the material comprising polyamide and glass fiber as thermoplastic resin (thermoplastic material). However, the molding material of the second holding member 2030 is not particularly limited.

[0629] (First slot)

[0630] As described above, the first groove 2024 of the first retaining member 2020 receives the protrusion 2032 of the second retaining member 2030. Fig.52As shown, when viewed in the axial direction of the first planar coil 2011, the protrusion 2032 is formed in an area on the second retaining member 2030 that overlaps with the area 2010MR on the coil intermediate material 2010M including the first planar coil 2011 and its center axis C1". Therefore, the first groove 2024 is also formed in the area 2020R1 on the contact surface 2020S1 corresponding to the above-mentioned area 2010MR. In the example shown in the figure, when viewed in the axial direction of the first planar coil 2011, the above-mentioned area 2010MR on the coil intermediate material 2010M and the above-mentioned area 2020R1 on the contact surface 2020S1 overlap.

[0631] In the example shown in the figure, the protrusion 2032 is formed along the spiral shape of the first planar coil 2011. Therefore, the first groove 2024 is also formed along the spiral shape of the first planar coil 2011 (see Fig.53 ). Furthermore, in the example shown in the figure, the protrusion 2032 is formed in a spiral shape corresponding to the spiral shape of the first planar coil 2011. Therefore, the first groove 2024 is also formed in a spiral shape corresponding to the spiral shape of the first planar coil 2011.

[0632] (Second slot)

[0633] The second groove 2025 is formed to suppress the warping of the first holding member 2020. According to the knowledge obtained by the inventors of the present application, the warping of the first holding member 2020 occurs when the first holding member 2020 is cooled and solidified, and the first holding member 2020 is heated and formed in the above-mentioned mold 2200. It is believed that this is because when the first holding member 2020 is cooled, the degree of contraction of the first holding member 2020 is different on the contact surface 2020S1 side and the outer surface 2020S2 side. In addition, it is believed that the difference in the degree of contraction of the first holding member 2020 on the contact surface 2020S1 side and the outer surface 2020S2 side is due to the different amount of material forming the first holding member 2020 on the contact surface 2020S1 side and the outer surface 2020S2 side of the first holding member 2020. That is, the first groove 2024 is formed on the contact surface 2020S1 of the first holding member 2020. Therefore, when the groove is not formed on the outer surface 2020S2 of the first holding member 2020, the amount of the material on the contact surface 2020S1 side of the first holding member 2020 is less than the amount of the material on the outer surface 2020S2 side by at least the volume of the first groove 2024. Therefore, in the present embodiment, it is considered that by forming the second groove 2025 on the outer surface 2020S2, the difference between the amount of the material on the contact surface 2020S1 side and the amount of the material on the outer surface 2020S2 side can be reduced, thereby suppressing the warping of the first holding member 2020.

[0634] The second groove 2025 is preferably formed in an area 2020R2 on the outer surface 2020S2 corresponding to the area 2020R1 on the contact surface 2020S1 where the first groove 2024 is formed. Thus, the difference between the degree of contraction of the first retaining member 2020 in each area on the contact surface 2020S1 and the degree of contraction of the first retaining member 2020 in each area on the outer surface 2020S2 corresponding to each area can be reduced, and the warping of the first retaining member 2020 can be effectively suppressed. In the example shown in the figure, when viewed in the axial direction of the first planar coil 2011, the above-mentioned area 2020R1 on the contact surface 2020S1 and the above-mentioned area 2020R2 on the outer surface 2020S2 overlap (refer to Fig.52 That is, when viewed in the axial direction of the first planar coil 2011, the second slot 2025 is formed in a region 2020R2 on the outer surface 2020S2 overlapping with a region 2020R1 on the contact surface 2020S1 including the center axis C1″ and the first slot 2024 (refer to Fig.52 and Fig.54 ).

[0635] Furthermore, in the example shown in the figure, the second groove 2025 is formed along the spiral shape of the first planar coil 2011 when viewed in the axial direction of the first planar coil 2011 (see Fig.54 and Fig.55 ). Thus, the difference between the degree of contraction of the first holding member 2020 in each area on the contact surface 2020S1 and the degree of contraction of the first holding member 2020 in each area on the outer surface 2020S2 corresponding to each area can be effectively reduced. Furthermore, in the example shown in the figure, as the first groove 2024 is formed into a spiral shape corresponding to the spiral shape of the first planar coil 2011, the second groove 2025 is also formed into a spiral shape corresponding to the spiral shape of the first planar coil 2011.

[0636] The width of the second groove 2025 is not particularly limited, and is, for example, 0.2 to 1.1 times the width of the first groove 2024. Thus, the warping of the first holding member 2020 can be effectively suppressed. In the example shown in the figure, the width of the second groove 2025 is substantially equal to the width of the first groove 2024. Specifically, the width of the second groove 2025 is 0.9 to 1.1 times the width of the first groove 2024. Thus, the warping of the first holding member 2020 can be further effectively suppressed.

[0637] In addition, the depth of the second groove 2025 is not particularly limited, and is, for example, 0.2 to 1.1 times the depth of the first groove 2024. Thus, the warping of the first holding member 2020 can be effectively suppressed. In the example shown in the figure, the depth of the second groove 2025 is actually equal to the depth of the first groove 2024. Specifically, the depth of the second groove 2025 is 0.9 to 1.1 times the depth of the first groove 2024. Accordingly, the warping of the first holding member 2020 can also be further effectively suppressed.

[0638] In addition, the volume of the second groove 2025 is not particularly limited, and is, for example, 0.2 to 1.1 times the volume of the first groove 2024. Thus, the warping of the first holding member 2020 can be effectively suppressed. In the example shown in the figure, the volume of the second groove 2025 is actually equal to the volume of the first groove 2024. Specifically, the volume of the second groove 2025 is 0.9 to 1.1 times the volume of the first groove 2024. Accordingly, the warping of the first holding member 2020 can also be further effectively suppressed.

[0639] In addition, in the example shown in the figure, the second slot 2025 does not overlap with the first slot 2024 when viewed in the axial direction of the first planar coil 2011. As a result, it is easy to make the depths of the first slot 2024 and the second slot 2025 to be the desired depths. In other words, it is possible to prevent the first slot 2024 and the second slot 2025 from being connected and forming a through hole in the first holding member 2020. Alternatively, it is possible to suppress the possibility that the distance between the bottom surface of the first slot 2024 and the outer surface 2020S2, and / or the distance between the bottom surface of the second slot 2025 and the contact surface 2020S1 is too small, thereby reducing the strength of the first holding member 2020 from being lower than the desired strength.

[0640] It should be noted that by forming the second groove 2025 on the outer surface 2020S2 of the first holding member 2020 , the heat dissipation performance of the coil component 2010 can also be improved.

[0641] (First Magnetic Shielding Member)

[0642] The first magnetic shielding member 2040 is provided to suppress magnetic permeation and / or leakage magnetic field. The first magnetic shielding member 2040 is a sheet-like member separate from the first planar coil 2011, the second planar coil 2012, the first holding member 2020, and the second holding member 2030. The first magnetic shielding member 2040 is separate from the first planar coil 2011, the second planar coil 2012, the first holding member 2020, and the second holding member 2030, which means that the first magnetic shielding member 2040 is not integrated with these first planar coil 2011, the second planar coil 2012, the first holding member 2020, and the second holding member 2030. However, the first magnetic shielding member 2040 and the second holding member 2030 may be bonded via an adhesive layer or the like. The first magnetic shielding member 2040 is formed to a size that includes the first planar coil 2011, the second planar coil 2012, and the second holding member 2030 when viewed from above. The first magnetic shielding member 2040 overlaps with the first planar coil 2011 , the second planar coil 2012 , and the second holding member 2030 , and is directly in contact with the second holding member 2030 .

[0643] The first magnetic shielding component 2040 of this embodiment has magnetism and contains a magnetic body or is composed of a magnetic body. In the coil component 2010, a magnetic field is generated when current is supplied to the first planar coil 2011 and the second planar coil 2012. The magnetic field generated in the coil component 2010 is generated in a manner that extends in all directions relative to the center axes C1” and C2” of the first planar coil 2011 and the second planar coil 2012. At this time, since the first magnetic shielding component 2040 has magnetism, the magnetic flux lines to be extended can be oriented toward the sides of the center axes C1” and C2”. In addition, the coil component 2010 can be set on the vehicle, but in this case, if the magnetic field generated in the coil component 2010 flows to the side of other vehicle parts, it sometimes has an adverse effect on the vehicle parts. In this case, the first magnetic shielding component 2040 can suppress the leakage magnetic field that does not contribute to the generation of current.

[0644] The first magnetic shielding member 2040 preferably includes a soft magnetic material or a nanocrystalline magnetic material. More specifically, the first magnetic shielding member 2040 includes ferrite, preferably a soft magnetic ferrite.

[0645] The relative magnetic permeability of the first magnetic shielding member 2040 may be greater than or equal to 500, or greater than or equal to 1000. The relative magnetic permeability of the first magnetic shielding member 2040 may be greater than or equal to 500 and less than or equal to 3000, or greater than or equal to 1000 and less than or equal to 3000. It should be noted that, as described above, the relative magnetic permeability in this specification is a value measured at a frequency of 85 kHz and an ambient temperature of 23 degrees.

[0646] (Second Magnetic Shielding Member)

[0647] The second magnetic shielding member 2050 is provided to cover the first magnetic shielding member 2040. In the present embodiment, the second magnetic shielding member 2050 is in contact with the first magnetic shielding member 2040, but instead of this, the second magnetic shielding member 2050 may be in contact with the first magnetic shielding member 2040 via a spacer. The second magnetic shielding member 2050 is formed of a metal material and has conductivity. Specifically, the second magnetic shielding member 2050 of the present embodiment is formed of aluminum. In this case, the magnetic flux is suppressed from leaking from the first planar coil 2011 and the second planar coil 2012 through the second magnetic shielding member 2050. It should be noted that the second magnetic shielding member 2050 may also be formed of an aluminum alloy, copper, stainless steel, etc.

[0648] (Connection terminal)

[0649] like Fig.50 and Fig.51 As shown, the first connection terminal 2061 is connected to the radially outer end of the turn portion 20115 in the first planar coil 2011. The second connection terminal 2062 is connected to the radially outer end of the turn portion 20125 in the second planar coil 2012. The first connection terminal 2061 and the second connection terminal 2062 can be used, for example, when connecting to the high-frequency current supply unit 1A or the conversion unit 2A. The connection between the first connection terminal 2061 and the turn portion 20115 and the connection between the second connection terminal 2062 and the turn portion 20125 can also be performed by ultrasonic bonding. However, there is no limitation on the connection method, and for example, a connection based on a conductive adhesive can also be used.

[0650] <Manufacturing method of coil component 2010>

[0651] Next, an example of a method for manufacturing coil device 2010 will be described. Fig.56 It is a perspective view of a mold 2200 for manufacturing the coil component 2010 . Fig.57 It means in Fig.56 The illustrated die 2200 is a cross-sectional view showing a state in which a first planar coil 2011 and a molding material 2220 described later are arranged.

[0652] First, prepare Fig.56 The mold 2200 shown, as Fig.57As shown, the first planar coil 2011 is arranged in the mold 2200. The mold 2200 has concavoconvexities corresponding to the concavoconvexities of the contact surface 2020S1 of the first holding member 2020. Specifically, the mold 2200 has a plate-shaped main body 2201, and the plate-shaped main body 2201 has a flat setting surface 2200S on which the first planar coil 2011 is placed. A convex portion 2202 protruding from the setting surface 2200S and extending in a spiral shape is formed on the main body 2201. The convex portion 2202 is a portion that forms the first groove 2024 of the first holding member 2020. In addition, the first planar coil 2011 is set in a spiral-shaped area on the setting surface 2200S that extends along the spiral-shaped convex portion 2202. When viewed in the axial direction of the first planar coil 2011, the convex portion 2202 is located between adjacent turns of the first planar coil 2011.

[0653] In addition, preparation for production Fig.54 and Fig.55 The material 2220 of the first holding member 2020 shown in the figure. In the example shown in the figure, the material 2220 is a formed material formed into a plate shape as a whole. A second groove 2025 is formed on one surface of the formed material 2220. Fig.57 As shown, the forming material 2220 is placed above the die 2200 and the first planar coil 2011. At this time, the forming material 2220 is placed above the die 2200 and the first planar coil 2011 in such a manner that the other side of the forming material 2220 (the side opposite to the side where the second groove 2025 is formed) faces the die 2200 and the first planar coil 2011. Next, the first planar coil 2011 and the forming material 2220 are hot stamped between the die 2200 and the other die 2210.

[0654] By hot stamping, the forming material 2220 softens and becomes molten. As a result, a groove corresponding to the protrusion 2202 of the mold 2200 is formed on the other surface of the forming material 2220. In this way, the first retaining member 2020 having the first groove 2024 is formed. When viewed in the axial direction of the first planar coil 2011, the first groove 2024 is formed between adjacent turns of the first planar coil 2011. In addition, the first retaining member 2020 is cooled and solidified, thereby integrating the first retaining member 2020 and the first planar coil 2011. In this way, the first retaining member 2020 is produced. Fig.53 Coil intermediate material 2010M is shown.

[0655] Next, the steps of integrating the second planar coil 2012 and the second holding member 2030 with the coil intermediate material 2010M are performed to manufacture the coil part 2010. It should be noted that, in the present embodiment, the forming material 2220 is melted between the dies 2200 and 2210 by hot stamping to form the coil intermediate material 2010M in which the first planar coil 2011 and the first holding member 2020 are integrated. However, this manufacturing method is an example. For example, the coil intermediate material 2010M can also be formed by injecting the forming material between the dies 2200 and 2210. In addition, when the forming material of the first holding member 2020 is hot stamped by the die 2210, the second groove 2025 can be formed on the first holding member 2020 by the die 2210.

[0656] <Applications of coil parts>

[0657] The coil component 2010 of the present embodiment can be used as a power transmission coil in the power transmission device 1 of the wireless power transmission system S described above, and can be used as a power reception coil in the power reception device 2 .

[0658] When the coil component 2010 is used as the power transmission coil, the first connection terminal 2061 and the second connection terminal 2062 are connected to Figure 1 , or an AC power source as shown in . When a high-frequency current is supplied to the coil part 2010, the current can flow from the first connection terminal 2061 to the first planar coil 2011 and the second planar coil 2012, and then flow from the second connection terminal 2062 to the high-frequency current supply unit 1A or the AC power source. In addition, the current can flow from the second connection terminal 2062 to the second planar coil 2012 and the first planar coil 2011, and then flow from the first connection terminal 2061 to the high-frequency current supply unit 1A or the AC power source. Thus, a magnetic field including magnetic lines of force along the central axis of the planar coil can be generated.

[0659] On the other hand, when the coil component 2010 is used as a power receiving coil, a magnetic field including magnetic lines of force is received or generated by passing through the inner sides of the first planar coil 2011 and the second planar coil 2012, thereby enabling the first planar coil 2011 and the second planar coil 2012 to generate a high-frequency current. Furthermore, the high-frequency current can be supplied from the first connection terminal 2061 or the second connection terminal 2062 to an external device.

[0660] In addition, the coil component 2010 can also be used in a transformer, an antenna, etc. For example, when the coil component 2010 functions as a primary coil in a transformer, the first connection terminal 2061 and the second connection terminal 2062 are connected to an AC power source. In addition, by supplying a high-frequency current, a magnetic flux can be supplied from the center side of the planar coil to the iron core.

[0661] <Modification>

[0662] It should be noted that various changes can be made to the above-mentioned embodiment. For example, coil device 2010 includes two planar coils 2011 and 2012, but the present invention is not limited thereto. The number of planar coils included in coil device 2010 may be 1 or 3 or more.

[0663] In addition, the coil component 2010 includes planar coils 2011, 2012 whose cross-sectional shape in the direction in which the planar coils 2011, 2012 are wound in a spiral shape is a rectangular plate-shaped planar coil 2011, 2012, but is not limited thereto. The planar coils 2011, 2012 may not be plate-shaped. The coil component 2010 may also include a planar coil formed by a stranded wire. The stranded wire is formed by twisting a plurality of conducting wires. In this case, the cross-sectional shape of the planar coil in the direction in which the planar coil is wound in a spiral shape may also be a circle.

[0664] In addition, in the above-mentioned embodiment, the second groove 2025 is formed on the outer surface 2020S2 of the first holding member 2020 to suppress the warping of the first holding member 2020, but the present invention is not limited thereto. Figures 58 to 60 As shown, at least one rib 2070 may be formed on the outer surface 2020S2 to suppress warping of the first holding member 2020. By forming the rib 2070 on the outer surface 2020S2, the rigidity of the outer surface 2020S2 of the first holding member 2020 is increased, and warping of the first holding member 2020 can be suppressed.

[0665] In the example shown in the figure, the rib 2070 is formed in a region 2020R2 on the outer surface 2020S2 overlapping with a region 2020R1 on the contact surface 2020S1 including the central axis C1″ of the first planar coil 2011 and the first slot 2024 (see Fig.59 and Fig.60 ). Thus, the rigidity of the outer surface 2020S2 of the first holding member 2020 can be increased in the portion where the first holding member 2020 is prone to warping, and the warping of the first holding member 2020 can be effectively suppressed.

[0666] In the example shown in the figure, a plurality of ribs 2070 extending in directions intersecting each other are formed on the outer surface 2020S2. This can suppress warping of the first holding member 2020 in a plurality of directions.

[0667] In the example shown in the figure, a plurality of ribs 2070 are formed in a grid pattern on the outer surface 2020S2 when viewed in the axial direction of the first planar coil 2011. This can effectively suppress warping of the first holding member 2020 in multiple directions.

[0668] It should be noted that by forming the ribs 2070 on the outer surface 2020S2 of the first holding member 2020 , the heat dissipation performance of the coil device 2010 can also be improved.

[0669] The coil component 2010 according to one embodiment described above comprises a planar coil 2011, a first holding member 2020, and a second holding member 2030. The planar coil 2011 has a spiral shape, and includes a first surface 2011A and a second surface 2011B extending on the central axis C1" of the spiral shape and axially opposite to each other. The first holding member 2020 overlaps with the planar coil 2011 in a manner opposite to the second surface 2011B of the planar coil 2011, thereby holding the planar coil 2011. The second holding member 2030 is integrated with the planar coil 2011 and the first holding member 2020 in a manner of clamping the planar coil 2011 with the first holding member 2020. The planar coil 2011 includes a plurality of turns 2011n arranged in the radial direction of the planar coil 2011. The second holding member 2030 has a planar shape. A protrusion 2032 extends along the above-mentioned axial direction between adjacent turns of the surface coil 2011. The first retaining member 2020 has a contact surface 2020S1 in contact with the second surface 2011B, and an outer surface 2020S2 on the side opposite to the contact surface 2020S1. A first groove 2024 is formed on the contact surface 2020S1 to accommodate the protrusion 2032. A second groove 2025 is formed on the outer surface 2020S2. The second groove 2025 is formed in an area 2020R2 on the outer surface 2020S2 that overlaps with an area 2020R1 on the contact surface 2020S1 including the center axis C1" and the first groove 2024 when viewed in the above-mentioned axial direction. According to this coil part 2010, the difference between the degree of contraction of the first retaining component 2020 in each area on the contact surface 2020S1 and the degree of contraction of the first retaining component 2020 in each area on the outer surface 2020S2 corresponding to each area can be reduced, and the warping of the first retaining component 2020 can be effectively suppressed.

[0670] In addition, in the embodiment described above, when viewed in the axial direction, the second groove 2025 is formed along the spiral shape of the planar coil 2011. Thus, the difference between the degree of contraction of the first holding member 2020 in each region on the contact surface 2020S1 and the degree of contraction of the first holding member 2020 in each region on the outer surface 2020S2 corresponding to each region can be effectively reduced.

[0671] In the above-described embodiment, the width of the second groove 2025 is 0.2 to 1.1 times the width of the first groove 2024. This can effectively suppress the warping of the first holding member 2020.

[0672] In the above-described embodiment, the depth of the second groove 2025 is 0.2 to 1.1 times the depth of the first groove 2024. This can effectively suppress the warping of the first holding member 2020.

[0673] In the above-described embodiment, the total volume of the second groove 2025 is 0.2 to 1.1 times the total volume of the first groove 2024. This can effectively suppress the warping of the first holding member 2020.

[0674] In addition, in the embodiment described above, when viewed in the axial direction, the second groove 2025 does not overlap with the first groove 2024. This makes it easy to make the depths of the first groove 2024 and the second groove 2025 desired.

[0675] In addition, the coil component 2010 based on the modified example described above includes a planar coil 2011, a first holding member 2020, and a second holding member 2030. The planar coil 2011 has a spiral shape, including a first surface 2011A and a second surface 2011B that are opposite to each other in the axial direction and extend on the central axis C1" of the spiral shape. The first holding member 2020 overlaps with the planar coil 2011 in a manner opposite to the second surface 2011B, thereby holding the planar coil 2011. The second holding member 2030 is integrated with the planar coil 2011 and the first holding member 2020 in a manner of clamping the planar coil 2011 with the first holding member 2020. The planar coil 2011 includes a plurality of turns 2011n arranged along the radial direction of the planar coil 2011. The second holding member 2030 has ... A protrusion 2032 extending along the above-mentioned axial direction between adjacent turns. The first retaining member 2020 has a contact surface 2020S1 in contact with the second surface 2011B, and an outer surface 2020S2 on the side opposite to the contact surface 2020S1. A first groove 2024 for accommodating the protrusion 2032 is formed on the contact surface 2020S1. At least one rib 2070 is formed on the outer surface 2020S2. At least one rib 2070 is formed in an area 2020R2 on the outer surface 2020S2 that overlaps with an area 2020R1 on the contact surface 2020S1 including the center axis C1" and the first groove 2024 when viewed in the above-mentioned axial direction. According to this coil part 2010, the rigidity of the outer surface 2020S2 of the first retaining member 2020 can be improved in the portion where the first retaining member 2020 is prone to warping, and the warping of the first retaining member 2020 can be effectively suppressed.

[0676] In the above-described modification, at least one rib 2070 includes a plurality of ribs 2070 extending in directions intersecting each other. This can suppress warping of the first holding member 2020 in a plurality of directions.

[0677] In the above-described modification, at least one rib 2070 includes a plurality of ribs 2070, and the plurality of ribs 2070 are formed in a lattice shape when viewed in the axial direction. This can effectively suppress warping of the first holding member 2020 in multiple directions.

[0678] In addition, in the one embodiment and the modified example described above, the first holding member 2020 is non-magnetic and insulating.

[0679] Furthermore, in the one embodiment and the modified example described above, the second holding member 2030 has magnetism.

[0680] Furthermore, in the above-described embodiment and modification examples, the planar coil 2011 is formed in a plate shape.

[0681] In the above-described modification, the planar coil 2011 is formed using litz wires.

[0682] The coil intermediate material 2010M according to one embodiment described above comprises a planar coil 2011 and a first holding member 2020. The planar coil 2011 has a spiral shape, and includes a first surface 2011A and a second surface 2011B extending on the central axis C1" of the spiral shape and axially opposite to each other. The first holding member 2020 overlaps with the planar coil 2011 in a manner opposite to the second surface 2011B, and holds the planar coil 2011. The planar coil 2011 includes a plurality of turns 2011n arranged along the radial direction of the planar coil 2011. The first holding member 2020 has a contact surface 2020S1 in contact with the second surface 2011B, and a contact surface 2020S1 in contact with the contact surface 2020S1. The outer surface 2020S2 on the opposite side. A first groove 2024 is formed on the contact surface 2020S1. A second groove 2025 is formed on the outer surface 2020S2. When viewed in the above-mentioned axial direction, the first groove 2024 is formed between adjacent turns of the planar coil 2011 along the spiral shape of the planar coil 2011. The second groove 2025 is formed in an area 2020R2 on the outer surface 2020S2 that overlaps with an area 2020R1 on the contact surface 2020S1 including the center axis C1″ and the first groove 2024 when viewed in the above-mentioned axial direction. According to this coil intermediate material 2010M, the difference in the degree of contraction of the first retaining member 2020 in each area on the contact surface 2020S1 and the degree of contraction of the first retaining member 2020 in each area on the outer surface 2020S2 corresponding to each area can be reduced, and the warping of the first retaining member 2020 can be effectively suppressed.

[0683] In addition, in the above-described modified example, when viewed in the axial direction, the second groove 2025 is formed along the spiral shape of the planar coil 2011. Thus, the difference between the degree of contraction of the first holding member 2020 in each region on the contact surface 2020S1 and the degree of contraction of the first holding member 2020 in each region on the outer surface 2020S2 corresponding to each region can be effectively reduced.

[0684] The coil intermediate material 2010M of the modified example described above includes a planar coil 2011 and a first holding member 2020. The planar coil 2011 has a spiral shape, and includes a first surface 2011A and a second surface 2011B that are axially opposite to each other and extend on the central axis C1" of the spiral shape. The first holding member 2020 overlaps with the planar coil 2011 in a manner opposite to the second surface 2011B, and holds the planar coil 2011. The planar coil 2011 includes a plurality of turns 2011n arranged in the radial direction of the planar coil. The first holding member 2020 has a contact surface 2020S1 that contacts the second surface 2011B, and a side opposite to the contact surface 2020S1. The outer surface 2020S2 is formed with a first groove 2024 on the contact surface 2020S1. At least one rib 2070 is formed on the outer surface 2020S2. When viewed in the above-mentioned axial direction, the first groove 2024 is formed between adjacent turns of the planar coil 2011 along the spiral shape of the planar coil 2011. At least one rib 2070 is formed in an area 2020R2 on the outer surface 2020S2 that overlaps with an area 2020R1 on the contact surface 2020S1 including the center axis C1″ and the first groove 2024 when viewed in the above-mentioned axial direction. According to this coil intermediate material 2010M, the rigidity of the outer surface 2020S2 of the first retaining component 2020 can be improved in the portion where the first retaining component 2020 is prone to warping, and the warping of the first retaining component 2020 can be effectively suppressed.

[0685] In the above-described modification, at least one rib 2070 includes a plurality of ribs 2070 extending in directions intersecting each other. This can suppress warping of the first holding member 2020 in a plurality of directions.

[0686] The power transmission device 1 and / or the power reception device 2 according to the above-described embodiment and its modified example include the above-described coil component 2010 .

[0687] The power transfer system S according to the embodiment and its modified example described above includes a power transmission device 1 and a power reception device 2. At least one of the power transmission device 1 and the power reception device 2 includes the coil component 2010 described above.

[0688] It should be noted that several modified examples with respect to the above-mentioned embodiment have been described above, and it is of course possible to appropriately combine and apply a plurality of modified examples.

[0689] <<<Fourth disclosed embodiment>>>

[0690] Hereinafter, embodiments of the fourth disclosure will be described with reference to the drawings.

[0691] <Coil parts>

[0692] Hereinafter, coil device 3010 according to one embodiment will be described. Fig.61 This is an exploded perspective view of coil component 3010 . Fig.62 It is a cross-sectional view of the coil component 3010 along the central axis C'" of the planar coil 3011 described later. Fig.63 3010M is a top view of the coil intermediate material 3010M described later. Fig.63 The hatching in the partial enlarged view is for easy identification of the components of the coil intermediate material 3010M, and does not represent the cross section of the components of the coil intermediate material 3010M.

[0693] like Fig.61 and Fig.62 As shown, the coil component 3010 includes a planar coil 3011, a first holding member 3020, and a second holding member 3030. In the example shown in the figure, the coil component 3010 also includes a first magnetic shielding member 3040, a second magnetic shielding member 3050, a first connecting terminal 3061, and a second connecting terminal 3062. The first holding member 3020, the planar coil 3011, the second holding member 3030, the first magnetic shielding member 3040, and the second magnetic shielding member 3050 are overlapped in sequence. The first connecting terminal 3061 and the second connecting terminal 3062 are overlapped in sequence. Fig.61 In addition, as described later, the planar coil 3011 and the first holding member 3020 form Fig.63 The coil intermediate material 3010M shown in FIG.

[0694] (Planar Coil)

[0695] The planar coil 3011 is spiral-shaped and is formed of a conductive material. In this embodiment, the planar coil 3011 contains copper. Specifically, the planar coil 3011 is formed of copper. However, the planar coil 3011 may also be formed of a copper alloy, aluminum, an aluminum alloy, or the like.

[0696] like Fig.61 As shown, the planar coil 3011 is in the shape of a plate. Fig.62 As shown, the cross-sectional shape of the planar coil 3011 in the direction perpendicular to the direction in which the planar coil 3011 is wound in a spiral shape, in other words, the direction in which the planar coil 3011 extends in a spiral shape is a rectangular shape.

[0697] Figure 61 to Figure 63The figure mark C'" shown represents the central axis (hereinafter, also referred to as the "coil central axis C'"') passing through the center of the spiral shape of the planar coil 3011. Hereinafter, the axial direction of the planar coil 3011 (hereinafter, also referred to as the "coil axial direction") refers to the direction extending on the coil central axis C'" or the direction parallel to the coil central axis C'"'. In addition, the radial direction of the planar coil 3011 (hereinafter, also referred to as the "coil radial direction") refers to the radial direction of a circle drawn on a plane orthogonal to the coil central axis C'"' with an arbitrary point on the coil central axis C'" as the center. The planar coil 3011 includes a first surface 3011A and a second surface 3011B. The first surface 3011A is opposite to the first retaining component 3020. The second surface 3011B is a surface on the opposite side of the first surface 3011A, and is opposite to the second retaining component 3030.

[0698] like Fig.61 As shown, the planar coil 3011 has a conductor 3011E formed into a spiral shape by a plurality of turns 3011n. The plurality of turns 3011n of the planar coil 3011 are arranged in a direction orthogonal to the central axis C'" of the coil. Specifically, the plurality of turns 3011n are connected so as to gradually move away from the central axis C'" of the coil toward the radial direction of the coil. Then, a spiral shape is formed thereby.

[0699] The turn 3011n is basically a linear conductor portion that is not in a ring shape and is wound 360 degrees around the center axis C'" of the coil. In the case of a so-called planar coil, the two ends of the turn 3011n deviate in the radial direction of the coil. Among the multiple turns 3011n, the outer end of a certain turn 3011n in the radial direction of the coil is connected to the inner end of another turn 3011n in the radial direction of the coil, and the other turn 3011n extends in a manner away from the center axis C'" of the coil.

[0700] In the following, the turn portion closest to the coil center axis C'' among the multiple turns 3011n is sometimes referred to as the turn portion 301101. In addition, the turn portion connected to the turn portion 301101 is sometimes referred to as the turn portion 301102. In the present embodiment, the multiple turns 3011n include 12 turns 301101 to 301112. In the following, when describing the common matters in each of the multiple turns 3011n, they are basically referred to as the turn portion 3011n.

[0701] In the present embodiment, the turn 3011n is wound in a manner to form an octagonal shape. More specifically, the turn 3011n is wound in a manner to form a regular octagonal shape. However, the turn 3011n may also be wound in a manner to form a polygonal shape other than an octagonal shape. For example, the turn 3011n may also be wound in a manner to form a dodecagonal shape or a regular dodecagonal shape. In addition, the turn 3011n may also be wound in a manner to form a circular shape. It should be noted that, as mentioned above, the vortex shape mentioned in this specification and the present disclosure refers to the shape of a plane curve wound into a spiral shape. The plane curve mentioned here also includes a plane pattern that is bent into a broken line shape as shown in the figure and is repeatedly wound. In addition, in other words, the vortex shape refers to the shape of a plane curve that moves away from the center as it turns (or approaches the center as it turns).

[0702] The radially inner end of the coil (the end close to the coil center axis C'") of the turn 301101 closest to the coil center axis C'" is electrically connected to the second connecting terminal 3062. On the other hand, the radially outer end (the end away from the coil center axis C'") of the turn 301112 farthest from the coil center axis C'" among the multiple turns 3011n is connected to the first connecting terminal 3061.

[0703] Here, the radial inner side (coil radial direction) of the planar coil 3011 (turn 3011n) refers to the direction approaching the coil center axis C'' in the radial direction. In addition, the radial outer side (coil radial direction) of the planar coil 3011 (turn 3011n) refers to the direction away from the coil center axis C'' in the radial direction. In addition, in the present embodiment, the coil center axis C'' is determined as follows. First, from the inner end of the coil radial direction of the turn 301102 adjacent to the innermost turn 301101, linear imaginary turns of a shape similar to the turn 301102 are sequentially drawn in a manner to form a vortex shape in the radial inner side. Then, the drawing is continued until an imaginary turn contained within a diameter of 1 cm can be drawn. Then, a line passing through the radial inner area of ​​the imaginary turn contained within a diameter of 1 cm in a direction orthogonal to the circumferential and radial directions of the vortex shape is determined as the coil center axis C''.

[0704] As an example, the planar coil 3011 described above is formed by punching a metal plate such as a copper plate or an aluminum plate into a spiral shape. Alternatively, the planar coil 3011 may be formed by etching a metal foil such as a copper foil or an aluminum foil into a spiral shape.

[0705] The thickness of the planar coil 3011 (the thickness of the conductor 3011E) may be, for example, greater than 0.1 mm and less than 1.0 mm. In addition, the radius of the planar coil 3011 (the distance from the center axis C'" of the coil to the portion radially farthest from the center axis C'" of the coil) may be greater than 80 mm, or greater than 80 mm and less than 450 mm. In addition, the aspect ratio of the planar coil 3011 (conductor 3011E) having a rectangular cross-sectional shape is determined by dividing the line width (the radial width of each turn 3011n) of the planar coil 3011 (conductor 3011E) by the thickness of the planar coil 3011 (conductor 3011E). The aspect ratio of the planar coil 3011 (conductor 3011E) may be greater than 2 and less than 12, or greater than 3 and less than 10.

[0706] In the case of transmitting power to an electric vehicle by magnetic field resonance, it is preferred that power of more than 1 kW, preferably more than 5 kW, can be transmitted in a frequency band of high-frequency current of preferably 10 kHz to 200 kHz, particularly 75 kHz to 100 kHz, and further 79 kHz to 90 kHz. In this case, the thickness of the planar coil 3011 formed of copper is preferably more than 0.2 mm. From this viewpoint, the lower limit of the thickness of the planar coil 3011 can also be set to 0.2 mm. In addition, in the case of transmitting power to an electric vehicle, it is not desired that the size is too large, and sometimes the size is limited. From this viewpoint, the planar coil 3011 (conductor 3011E) is preferably formed in a size that is accommodated in a square with a side of 800 mm.

[0707] In addition, the line width of the planar coil 3011 (the line width of the conductor 3011E), that is, the radial width of the coil (the width in the radial direction of the coil) of each turn portion 3011n is not particularly limited. However, for example, when considering that an electric power of more than 1 kW, preferably more than 5 kW, can be transmitted in the frequency band of high-frequency current of 79 kHz to 90 kHz, the radial width of the coil of the turn portion 3011n can be more than 2 mm and less than 20 mm, or more than 2 mm and less than 16 mm, more than 2 mm and less than 12 mm, or more than 2 mm and less than 8 mm. In addition, the number of turns of the planar coil 3011 is not particularly limited, and can be less than 11 or more than 13.

[0708] (First Holding Member)

[0709] The first holding member 3020 overlaps the planar coil 3011 so as to face the first surface 3011A of the planar coil 3011, and holds the planar coil 3011. In the coil component 3010, for example, when power is transmitted, the magnetic field generated in the planar coil 3011 passes through the first holding member 3020. Therefore, in order not to hinder the magnetic field and in order not to generate eddy current, the first holding member 3020 is preferably non-conductive (insulating) and non-magnetic.

[0710] Considering that it is preferably non-conductive (insulating) and non-magnetic, the material of the first holding member 3020 is, for example, a resin, or a fiber-reinforced plastic. More specifically, the material of the first holding member 3020 may also be glass fiber reinforced polyamide. However, there is no particular limitation on the material of the first holding member 3020. For example, it may not contain glass fiber. In addition, thermoplastic resins or thermosetting resins other than polyamide may also be used. It should be noted that, as mentioned above, insulation refers to a volume resistivity of 10 10 Ω·m or more. Nonmagnetic means not showing magnetism.

[0711] The first holding member 3020 is integrated with the planar coil 3011 to hold the planar coil 3011. In this embodiment, the molds 3201 and 3202 (see Fig.64 ) after configuring the planar coil 3011 (refer to Fig.65 ), the material 3220 for making the first holding member is pressed into the above-mentioned molds 3201 and 3202 by hot stamping to be formed (refer to Fig.66 ), the material is cooled and solidified, thereby integrating the planar coil 3011 and the first holding member 3020. In this specification, the member integrating the first holding member 3020 and the planar coil 3011 is referred to as the coil intermediate material 3010M.

[0712] In the present embodiment, the first holding member 3020 and the second holding member 3030 sandwich the planar coil 3011. In the illustrated example, the first holding member 3020 has a first contact surface 3020S1 that contacts the first surface 3011A of the planar coil 3011, and a second contact surface 3020S2 that contacts the base 3031 of the second holding member 3030 described later. The height position (position in the axial direction of the coil) of the first contact surface 3020S1 is the same as the height position of the first surface 3011A of the planar coil 3011. The height position (position in the axial direction of the coil) of the second contact surface 3020S2 is the same as the height position of the second surface 3011B of the planar coil 3011. The contact surfaces 3020S1 and 3020S2 form a part of the inner surface of the first holding member 3020. In addition, the first holding member 3020 has a surface opposite to the contact surfaces 3020S1 and 3020S2, that is, an outer surface 3020S3.

[0713] like Fig.63 and Fig.64 As shown in FIG. 1 , a groove 3024 for receiving a wall portion 3032 of a second holding member 3030 described later is formed on the first holding member 3020. The groove 3024 will be described in detail later.

[0714] In the example shown in the figure, a portion of the first holding member 3020 forms a covering portion 3028 covering the side surfaces of each turn portion 3011n of the planar coil 3011. The covering portion 3028 is a portion of the first holding member 3020 between the first contact surface 3020S1 and the second contact surface 3020S2. The covering portion 3028 extends from the first contact surface 3020S1 toward the coil axial direction on both sides of the opening portion 3024b of the slot 3024. The covering portion 3028 forms the second contact surface 3020S2. The space surrounded by the covering portion 3028 is connected to the internal space of the slot 3024.

[0715] (Second Holding Member)

[0716] like Fig.62 As shown, the second holding member 3030 and the first holding member 3020 of this embodiment sandwich the planar coil 3011. In the example shown in the figure, the second holding member 3030, the planar coil 3011 and the first holding member 3020 are integrated.

[0717] In detail, the second holding member 3030 includes a base 3031 disposed between the planar coil 3011 and the first magnetic shielding member 3040, and a wall 3032 protruding from the base 3031 toward the first holding member 3020 in the axial direction of the coil. The base 3031 is opposite to the second surface 3011B of the planar coil 3011. The base 3031 entirely covers the second surface 3011B of the planar coil 3011. When viewed in the axial direction of the planar coil 3011, the base 3031 is formed to a size that includes the entirety of the planar coil 3011. The base 3031 and the first holding member 3020 sandwich the planar coil 3011 therebetween. In the example shown in the figure, the base 3031 is in contact with the second surface 3011B of the planar coil 3011. However, another layer may be arranged between the base 3031 and the second surface 3011B of the planar coil 3011.

[0718] The wall portion 3032 extends between adjacent turns of the planar coil 3011. Therefore, the wall portion 3032 is formed along the spiral-shaped planar coil 3011. In the illustrated example, the wall portion 3032 is formed into a spiral shape corresponding to the spiral shape of the planar coil 3011. As described above, the wall portion 3032 is accommodated in the groove 3024 of the first holding member 3020. In other words, the wall portion 3032 is filled into the groove 3024 in the first holding member 3020.

[0719] The second holding member 3030 has magnetism as a whole. That is, the base 3031 and the wall portion 3032 have magnetism respectively. The second holding member 3030 suppresses eddy current loss and leakage flux through magnetism, or improves the coupling coefficient, thereby achieving improved coil performance. The relative magnetic permeability of the second holding member 3030 is preferably greater than 2.0, and may be greater than 2.0 and less than 10.0. The relative magnetic permeability of the second holding member 3030 is more preferably greater than 5.0, and may be greater than 5.0 and less than 10.0. There is no particular restriction on the relative magnetic permeability of the second holding member 3030, but if it is too large, the flexibility or strength of the second holding member 3030 is sometimes unexpectedly damaged. Therefore, the relative magnetic permeability of the second holding member 3030 may also be less than 200.

[0720] In addition, by providing the second holding member 3030 with a wall portion 3032, the coil performance can be effectively improved. The height 3032H of the wall portion 3032 (the distance between the top 3032a of the wall portion 3032 and the second surface 3011B of the planar coil 3011 along the axial direction of the planar coil 3011) is not particularly limited, for example, it can be more than 0.5mm, or it can be more than 1.0mm. The higher the height 3032H of the wall portion 3032 is, more specifically, the higher the protruding height 3032Ha of the wall portion 3032 from the planar coil 3011 is, the higher the effect of suppressing eddy current loss is and the tendency of improving the coupling coefficient is. On the other hand, the higher the wall portion 3032 is, the easier it is to be damaged starting from the lower part. Therefore, the above-mentioned protruding height 3032Ha of the wall portion 3032 can also be, for example, less than 10mm. It should be noted that the protrusion height 3032Ha of the wall portion 3032 from the planar coil 3011 is the distance between the top 3032a of the wall portion 3032 and the first surface 3011A. The wall portion 3032 will be described in further detail later.

[0721] As an example, the second holding member 3030 of this embodiment includes a resin and a plurality or countless magnetic particles made of a magnetic body. The magnetic particles are held in the resin as a holding material.

[0722] The magnetic particles can also be formed by any one or more of ferrite, particularly ferrite of soft magnetic material, nanocrystalline magnetic body, silicon steel, electromagnetic soft iron, and amorphous metal. The resin as the holding material can also be glass fiber reinforced polyamide. That is, the resin can also be formed by the material comprising polyamide and glass fiber as thermoplastic resin (thermoplastic material). However, the molding material of the second holding member 3030 is not particularly limited.

[0723] (First Magnetic Shielding Member)

[0724] The first magnetic shielding member 3040 is provided to suppress magnetic permeation and / or leakage magnetic field. The first magnetic shielding member 3040 is a sheet-like member separate from the planar coil 3011, the first holding member 3020, and the second holding member 3030. The first magnetic shielding member 3040 is separate from the planar coil 3011, the first holding member 3020, and the second holding member 3030, which means that the first magnetic shielding member 3040 is not integrated with these planar coils 3011, the first holding member 3020, and the second holding member 3030. However, the first magnetic shielding member 3040 and the second holding member 3030 may also be joined via an adhesive layer or the like. The first magnetic shielding member 3040 is formed to include the planar coil 3011 and the second holding member 3030 in a plan view. The first magnetic shielding member 3040 overlaps with the planar coil 3011 and the second holding member 3030. The first magnetic shielding member 3040 may also be directly connected to the second holding member 3030. Alternatively, another layer formed of a heat dissipation material or the like may be disposed between the first magnetic shield member 3040 and the second holding member 3030 .

[0725] The first magnetic shielding component 3040 of the present embodiment has magnetism and contains a magnetic body or is composed of a magnetic body. In the coil part 3010, a magnetic field is generated when current is supplied to the planar coil 3011. The magnetic field generated in this coil part 3010 is generated in a manner that extends in all directions relative to the center axis C'" of the coil. At this time, since the first magnetic shielding component 3040 has magnetism, the magnetic flux lines to be extended can be oriented toward the side of the center axis C'" of the coil. In addition, the coil part 3010 can be set on the vehicle, but in this case, if the magnetic field generated in the coil part 3010 flows to the side of other vehicle parts, it sometimes has an adverse effect on the vehicle parts. In this case, the first magnetic shielding component 3040 can suppress the leakage magnetic field that does not contribute to the generation of current.

[0726] The first magnetic shielding member 3040 preferably includes a soft magnetic material or a nanocrystalline magnetic material. More specifically, the first magnetic shielding member 3040 includes ferrite, preferably a soft magnetic ferrite.

[0727] The relative magnetic permeability of the first magnetic shielding member 3040 may be greater than or equal to 500, or greater than or equal to 1000. The relative magnetic permeability of the first magnetic shielding member 3040 may be greater than or equal to 500 and less than or equal to 3000, or greater than or equal to 1000 and less than or equal to 3000. It should be noted that, as described above, the relative magnetic permeability in this specification is a value measured at a frequency of 85 kHz and an ambient temperature of 23 degrees.

[0728] (Second Magnetic Shielding Member)

[0729] The second magnetic shielding member 3050 is provided to cover the first magnetic shielding member 3040. The second magnetic shielding member 3050 may be directly connected to the first magnetic shielding member 3040. Alternatively, another layer or spacer formed of a heat dissipation material or the like may be arranged between the second magnetic shielding member 3050 and the first magnetic shielding member 3040. The second magnetic shielding member 3050 is formed of a metal material and has conductivity. Specifically, the second magnetic shielding member 3050 of the present embodiment is formed of aluminum. In this case, the magnetic flux is suppressed from leaking from the planar coil 3011 through the second magnetic shielding member 3050. It should be noted that the second magnetic shielding member 3050 may also be formed of an aluminum alloy, copper, stainless steel, or the like. When the coil component 3010 is mounted on a car, the second magnetic shielding member 3050 may be a metal plate constituting the body (car body) of the car.

[0730] (Connection terminal)

[0731] like Fig.61 As shown, the first connection terminal 3061 is connected to the radially outer end of the turn portion 301112 in the planar coil 3011. The second connection terminal 3062 is connected to the radially inner end of the turn portion 301101 in the planar coil 3011. The first connection terminal 3061 and the second connection terminal 3062 can be used, for example, when connecting to the high-frequency current supply unit 1A or the conversion unit 2A. The connection between the first connection terminal 3061 and the turn portion 301112 and the connection between the second connection terminal 3062 and the turn portion 301101 can also be performed by ultrasonic bonding. However, there is no limitation on the connection method, and for example, a connection based on a conductive adhesive can also be used.

[0732] (groove and wall)

[0733] As described above, the groove 3024 of the first holding member 3020 accommodates the wall portion 3032 of the second holding member 3030. The wall portion 3032 extends between adjacent turns of the planar coil 3011. Correspondingly, the groove 3024 is formed between adjacent turns of the planar coil 3011 when viewed in the axial direction of the coil. In the illustrated example, the wall portion 3032 is also formed on the outer side of the outermost turn 301112 in the coil radial direction. Correspondingly, the groove 3024 is also formed on the outer side of the outermost turn 301112 in the coil radial direction. In addition, in the illustrated example, the wall portion 3032 is also formed on the inner side of the innermost turn 301101 in the coil radial direction. Correspondingly, the groove 3024 is also formed on the inner side of the innermost turn 301101 in the coil radial direction.

[0734] In addition, in the example shown in the figure, the wall portion 3032 is formed along the spiral shape of the planar coil 3011. Therefore, the groove 3024 is also formed along the spiral shape of the planar coil 3011. Furthermore, in the example shown in the figure, the wall portion 3032 is formed in a spiral shape corresponding to the spiral shape of the planar coil 3011. Therefore, the groove 3024 is also formed in a spiral shape corresponding to the spiral shape of the planar coil 3011.

[0735] The groove 3024 opens on the first contact surface 3020S1. In other words, the groove 3024 has an opening portion 3024b formed on the first contact surface 3020S1. The wall portion 3032 extends into the groove 3024 through the opening portion 3024b. The groove 3024 has a bottom 3024a. One side that divides the groove 3024 includes a side surface 3024c (hereinafter also referred to as "groove side surface 3024c") between the opening portion 3024b and the bottom 3024a. The groove side surface 3024c includes a pair of groove side surfaces 3024ca and 3024cb facing each other in the radial direction of the coil. The pair of groove side surfaces 3024ca and 3024cb have an inner groove side surface 3024ca located on the inner side in the radial direction of the coil, and an outer groove side surface 3024cb located on the outer side in the radial direction of the coil.

[0736] The wall portion 3032 has a top 3032a and a base end 3032b. The wall portion 3032 is connected to the base 3031 at the base end 3032b. The wall portion 3032 has a side 3032c (hereinafter also referred to as "wall side 3032c") between the top 3032a and the base end 3032b. The top 3032a is opposite to the bottom 3024a of the groove 3024. In the illustrated example, the top 3032a is in contact with the bottom 3024a. The wall side 3032c includes an inner wall side 3032ca facing the inner side of the coil radial direction, and an outer wall side 3032cb facing the outer side of the coil radial direction. The inner wall side 3032ca and the outer wall side 3032cb of the wall portion 3032 are respectively opposite to the inner groove side 3024ca and the outer groove side 3024cb of the groove 3024. In the example shown in the figure, the inner wall side surface 3032ca and the outer wall side surface 3032cb of the wall portion 3032 are in contact with the inner groove side surface 3024ca and the outer groove side surface 3024cb of the groove 3024, respectively.

[0737] Here, when the width (dimension along the radial direction of the coil) of the wall portion 3032 is uniform in its protruding direction (axial direction of the coil) as in the wall of the magnetic body disclosed in JP2023-88728A, Fig.75 As shown, the width of the groove 3024 of the first holding member 3020 (the dimension along the radial direction of the coil) also needs to be uniform in its depth direction (the axial direction of the coil). Fig.76The mold 3302 is formed in the molds 3301 and 3302 as shown. The mold 3302 has a main body 3303 and a convex portion 3304 extending from the main body 3303. The convex portion 3304 corresponds to the groove 3024 and is formed into a spiral shape. The width of the convex portion 3304 (the radial dimension of the convex portion 3304) is uniform in the protruding direction of the convex portion 3304. Here, the radial direction of the convex portion 3304 refers to the radial direction of a circle drawn on a plane orthogonal to the central axis C3302 with an arbitrary point on the central axis C3302 of the convex portion 3304 as the center. The central axis C3302 of the convex portion 3304 is a line passing through the center of the spiral shape.

[0738] As described above, there is a tendency that the higher the height of the wall portion 3032, the higher the eddy current loss suppression effect and the higher the coupling coefficient. The higher the height of the wall portion 3032 needs to be, the deeper the groove 3024 of the first retaining member 3020 needs to be. The deeper the depth of the groove 3024, the more difficult it is to form a groove 3024 having a uniform width in the depth direction on the first retaining member 3020. Specifically, the deeper the protrusion 3304 of the mold 3302 is pressed into the material 3220, the more difficult it is for the material 3220 in the portion where the protrusion 3304 is pressed to flow. Furthermore, in the case where the material 3220 contains glass fibers, when the mold 3302 is pressed into the material 3220, the glass fibers in the material 3220 contact the top surface of the protrusion 3304, preventing the mold 3302 from entering the material 3220. If the mold 3302 is forcibly pressed into the material 3220, the mold 3302 may be damaged. Therefore, it is difficult to utilize Fig.76 The die 3302 shown forms a deep groove 3024 in the first holding member 3020. The depth of the groove 3024 that can be formed in the first holding member 3020 using the die 3302 is at most 2 mm.

[0739] Furthermore, as the height of the wall portion 3032 is increased, the remaining material 3220 between the bottom 3024a of the groove 3024 of the first holding member 3020 and the outer surface 3020S3 decreases, and therefore, there is a concern that the strength of the first holding member 3020 may decrease. If the strength of the first holding member 3020 decreases, the strength of the coil component 3010 also decreases.

[0740] Considering the above points, the width of the bottom 3024a of the groove 3024 of the first holding member 3020 of the present embodiment (the dimension along the radial direction of the coil) is narrower than the width at the height position of the first contact surface 3020S1 of the groove 3024 (the dimension along the radial direction of the coil). Correspondingly, the width of the top 3032a of the wall portion 3032 of the second holding member 3030 (the dimension along the radial direction of the coil) is narrower than the width at the height position of the first contact surface 3020S1 of the wall portion 3032 (the dimension along the radial direction of the coil).

[0741] The first holding member 3020 having such a groove 3024 can be used Fig.64 The mold 3202 is formed as shown. That is, the mold 3202 has a main body 3203 and a convex portion 3204 extending from the main body 3203. The convex portion 3204 has a spiral shape corresponding to the spiral shape of the groove 3024. Therefore, the convex portion 3204 corresponds to the shape of the gap extending between the adjacent turns of the planar coil 3011. The convex portion 3204 has a top 3204a and a base end 3204b. The convex portion 3204 is connected to the main body 3203 at the base end 3204b.

[0742] Fig.64 The reference numeral C3202 shown in the figure represents the central axis (hereinafter, also referred to as the "mold central axis C3202") passing through the center of the spiral shape of the convex portion 3204. Hereinafter, the axial direction of the convex portion 3204 (hereinafter, also referred to as the "mold axial direction") refers to the direction extending on the mold central axis C3202 or the direction parallel to the mold central axis C3202. In addition, the radial direction of the convex portion 3204 (hereinafter, also referred to as the "mold radial direction") refers to the radial direction of a circle drawn on a plane orthogonal to the mold central axis C3202 with an arbitrary point on the mold central axis C3202 as the center.

[0743] In the present embodiment, the width of the top 3204a (the dimension along the radial direction of the mold) is narrower than the width of the base end 3204b (the dimension along the radial direction of the mold). Since the protrusion 3204 of the mold 3202 has such a shape, when the protrusion 3204 is pressed into the material 3220, the material 3220 of the portion where the protrusion 3204 is pressed can be guided in the width direction of the protrusion 3204. In other words, the shape of the protrusion 3204 can promote the flow of the material 3220 of the portion where the protrusion 3204 is pressed. Therefore, it is easy to press the protrusion 3204 deeper into the material 3220. In addition, in the case where the material 3220 contains glass fiber, since the width of the top 3204a of the protrusion 3204 is narrower than the width of the base end 3204b, the area of ​​the portion (top 3204a) in contact with the glass fiber of the protrusion 3204 is smaller than that of the base end 3204b. Fig.76 As a result, even if the convex portion 3204 is pressed deeply into the material 3220, the possibility of the convex portion 3204 being damaged can be suppressed. As described above, according to the mold 3202 of this embodiment, it is easy to form a deep groove 3024 on the first holding member 3020. This makes it easy to form the first holding member 3020. In addition, by deepening the groove 3024 of the first holding member 3020, the height 3032H of the wall portion 3032 can be increased, and the performance of the coil component 3010 is improved.

[0744] From the viewpoint of effectively concentrating the pressing force applied to the mold 3202 on the top 3204a, the width of the top 3204a is preferably less than half of the width of the base end 3204b, and more preferably less than one-third.

[0745] Furthermore, even if a deep groove 3024 is formed in the first holding member 3020, since the width of the bottom 3024a is narrow, more material 3220 can remain between the groove 3024 and the outer surface 3020S3 of the first holding member 3020. Thus, the strength of the first holding member 3020 is suppressed from decreasing, and the strength of the coil component 3010 is also suppressed from decreasing.

[0746] exist Fig.64 In the example shown, the convex portion 3204 also forms a space surrounded by the covering portion 3028 on the first holding member 3020. The width of a portion 3204d (hereinafter also referred to as "base end portion 3204d") of the convex portion 3204 that is continuous with the base end 3204b is uniform in the axial direction of the mold, so that the width of the space (the dimension along the radial direction of the coil) is uniform in the axial direction of the coil.

[0747] It should be noted that the width of a portion 3032d (hereinafter also referred to as "base end portion 3032d") of the wall portion 3032 which is continuous with the base end 3032b is also uniform in the axial direction of the coil, corresponding to the space surrounded by the covering portion 3028. In the example shown in the figure, the base end portion 3032d is continuous to the height position of the first surface 3011A of the planar coil 3011.

[0748] In the example shown in the figure, at least one of the pair of groove side surfaces 3024ca, 3024cb of the dividing groove 3024 has an inclined surface 3024s inclined relative to the axial direction of the coil (therefore, relative to the central axis C'" of the coil). Correspondingly, at least one of the pair of wall side surfaces 3032ca, 3032cb of the wall portion 3032 has an inclined surface 3032s inclined relative to the axial direction of the coil (therefore, relative to the central axis C'" of the coil). It should be noted that the first retaining component 3020 having such a groove 3024 can be formed using a mold 3202 as follows. That is, as Fig.64As shown, the convex portion 3204 of the mold 3202 has a side surface 3204c (hereinafter also referred to as "mold side surface 3204c") between the top 3204a and the base end 3204b. The mold side surface 3204c includes a pair of mold side surfaces 3204ca and 3204cb that are opposite to each other in the mold radial direction. The pair of mold side surfaces 3204ca and 3204cb include an inner mold side surface 3204ca located on the inner side in the mold radial direction, and an outer mold side surface 3204cb located on the outer side in the mold radial direction. At least one of the pair of mold side surfaces 3204ca and 3204cb has an inclined surface 3204s inclined relative to the mold axial direction (therefore, relative to the mold center axis C3202).

[0749] exist Fig.62 In the example shown, the outer groove side surface 3024cb of the groove 3024 has an inclined surface 3024s. Correspondingly, the outer wall side surface 3032cb of the wall portion 3032 has an inclined surface 3032s. In addition, the outer mold side surface 3204cb of the mold 3202 has an inclined surface 3204s (see Fig.64 ). More specifically, Fig.62 As shown, the inclined surface 3024s of the outer groove side surface 3024cb is inclined relative to the coil axial direction in a manner close to the coil center axis C"' from the opening portion 3024b toward the bottom 3024a. Similarly, the inclined surface 3032s of the outer wall side surface 3032cb is inclined relative to the coil axial direction in a manner close to the coil center axis C"' from the base end 3032b toward the top 3032a. In addition, as Fig.64 As shown, the inclined surface 3204s of the outer mold side surface 3204cb is inclined relative to the mold axial direction in a manner approaching the mold center axis C3202 from the base end 3204b toward the top 3204a.

[0750] exist Fig.62 In the example shown, the inner slot side surface 3024ca is parallel to the coil axial direction from the opening 3024b to the bottom 3024a. In addition, the inclined surface 3024s of the outer slot side surface 3024cb is continuous from the opening 3024b to the bottom 3024a.

[0751] In addition, Fig.62 In the example shown, the inner wall side surface 3032ca of the wall portion 3032 is parallel to the coil axis from the base end 3032b to the top 3032a. In addition, the area between the base end 3032b and the inclined surface 3032s in the outer wall side surface 3032cb of the wall portion 3032 is parallel to the coil axis. This area corresponds to the base end portion 3032d mentioned above. Fig.62In the example shown, the inclined surface 3032s is continuous from the height position of the first surface 3011A of the outer wall side surface 3032cb to the top 3032a. Therefore, the height position of the outer wall side surface 3032cb from the base end 3032b to the first surface 3011A is parallel to the coil axis. Fig.62 In the example shown, the dimension of the base end 3032d of the wall portion 3032 (a portion connected to the base end 3032b and having a uniform width in the coil axial direction) along the coil axial direction is the same as the thickness of the planar coil 3011. Therefore, the base end 3032d does not protrude from the first surface 3011A of the planar coil 3011.

[0752] In addition, in this example, Fig.64 As shown, the inner mold side surface 3204ca of the protrusion 3204 is parallel to the mold axis from the base end 3204b to the top 3204a. In addition, the area 3204cd between the base end 3204b and the inclined surface 3204s in the outer mold side surface 3204cb of the protrusion 3204 is parallel to the mold axis. This area corresponds to the base end 3204d mentioned above. The dimension of this area 3204cd along the mold axis is the same as the thickness of the planar coil 3011. The inclined surface 3204s is continuous from the end edge of the area 3204cd on the opposite side of the base end 3204b to the top 3032a.

[0753] <Method for manufacturing coil component 3010>

[0754] Next, an example of a method for manufacturing coil device 3010 will be described.

[0755] First, prepare Fig.64 The molds 3201, 3202 shown in FIG. Fig.65 As shown, the planar coil 3011 is arranged on the main body 3203 of the mold 3202. At this time, the planar coil 3011 is arranged on the main body 3203 in such a manner that the protrusion 3204 of the mold 3202 protrudes from between adjacent turns of the planar coil 3011.

[0756] In addition, a material 3220 for manufacturing the first holding member is prepared. In the example shown in the figure, the material 3220 is a molding material formed into a plate shape as a whole. Next, the molding material 220 is heated. Fig.65 As shown in FIG. 3 , the molding material 3220 is placed on the mold 3202 and the planar coil 3011. Fig.66 As shown, the planar coil 3011 and the forming material 3220 are hot stamped between the mold 3202 and another mold 3201.

[0757] The forming material 3220 softens and becomes molten between the molds 201 and 202. As a result, a groove 3024 corresponding to the protrusion 3204 of the mold 3202 is formed on one side of the forming material 3220. In this way, the first retaining member 3020 having the groove 3024 is formed. When viewed in the axial direction of the coil, the groove 3024 is formed between adjacent turns of the planar coil 3011. In addition, the first retaining member 3020 is cooled and solidified, and the first retaining member 3020 and the planar coil 3011 are integrated. In this way, the first retaining member 3020 is manufactured. Fig.63 Coil intermediate material 3010M is shown.

[0758] After removing the mold 3202 from the coil intermediate material 3010M, as shown in FIG. Fig.67 As shown, the second holding member 3030 is formed on the coil intermediate material 3010M (more specifically, on the second surface 3011B of the planar coil 3011). At this time, the groove 3024 is filled with the second holding member 3030. The second holding member 3030 is integrated with the coil intermediate material 3010M. Then, the first magnetic shielding member 3040 and the second magnetic shielding member 3050 are arranged on the second holding member 3030. Through the above, the coil part 3010 is manufactured.

[0759] <Applications of coil parts>

[0760] The coil component 3010 of the present embodiment can be used as a power transmission coil in the power transmission device 1 of the wireless power transmission system S described above, and can be used as a power reception coil in the power reception device 2 .

[0761] When the coil component 3010 is used as the power transmission coil, the first connection terminal 3061 and the second connection terminal 3062 are connected to Figure 1 The high-frequency current supply unit 1A or AC power supply is connected as shown. When a high-frequency current is supplied to the coil part 3010, the current can flow from the first connecting terminal 3061 to the planar coil 3011, and then flow from the second connecting terminal 3062 to the high-frequency current supply unit 1A or the AC power supply. In addition, the current can flow from the second connecting terminal 3062 to the planar coil 3011, and then flow from the first connecting terminal 3061 to the high-frequency current supply unit 1A or the AC power supply. Thus, a magnetic field containing magnetic lines of force along the center axis C"' of the coil can be generated.

[0762] On the other hand, when the coil component 3010 is used as a power receiving coil, a magnetic field including magnetic lines of force is received or generated by passing through the inner side of the planar coil 3011, thereby enabling the planar coil 3011 to generate a high-frequency current. Furthermore, the high-frequency current can be supplied from the first connection terminal 3061 or the second connection terminal 3062 to an external device.

[0763] In addition, the coil component 3010 can also be used in a transformer, an antenna, etc. For example, when the coil component 3010 functions as a primary coil in a transformer, the first connection terminal 3061 and the second connection terminal 3062 are connected to an AC power source. Then, by supplying a high-frequency current, a magnetic flux can be supplied from the center side of the planar coil 3011 to the iron core.

[0764] <Modification>

[0765] It should be noted that various changes can be made to the above-mentioned one embodiment. For example, the coil part 3010 may also include a plurality of planar coils. More specifically, the coil part 3010 may include another planar coil between the planar coil 3011 and the first magnetic shielding part 3040. The number of planar coils contained in the coil part 3010 is not particularly limited. In the case where the coil part 3010 includes the above-mentioned other planar coil, the planar coil 3011 and the other planar coil may be stacked along the coil axis of the planar coil 3011. In this case, the other planar coil may be buried in the base 3031 of the second holding part 3030. In addition, in this case, one of the connecting terminals 3061, 3062 may be connected to the planar coil 3011, and the other of the connecting terminals 3061, 3062 may be connected to the other planar coil. In addition, in this case, the planar coil 3011 and the other planar coil may be electrically connected.

[0766] In addition, the shapes of the groove 3024, the wall portion 3032 and the protrusion 3204 are not limited to the above-mentioned shapes. Fig.68 As shown, the inner groove side surface 3024ca of the groove 3024 may also have an inclined surface 3024s inclined relative to the coil axial direction. Correspondingly, the inner wall side surface 3032ca of the wall portion 3032 may also have an inclined surface 3032s inclined relative to the coil axial direction. In addition, although not shown, the inner mold side surface 3204ca of the mold 3202 may also have an inclined surface 3204s inclined relative to the mold axial direction.

[0767] In this case, the inclined surface 3024s of the inner groove side surface 3024ca is inclined relative to the axial direction of the coil in a manner that moves away from the coil center axis C'" from the opening portion 3024b toward the bottom 3024a. Similarly, the inclined surface 3032s of the inner wall side surface 3032cb is inclined relative to the axial direction of the coil in a manner that moves away from the coil center axis C'" from the base end 3032b toward the top 3032a. In addition, the inclined surface 3204s of the inner mold side surface 3204ca is inclined relative to the mold axial direction in a manner that moves away from the mold center axis C3202 from the base end 3204b toward the top 3204a.

[0768] It should be noted that according to the insights obtained by the inventors, Fig.62Compared with the case where the outer wall side surface 3032cb has the inclined surface 3032s and the inner wall side surface 3032ca does not have the inclined surface 3032s as shown in FIG. Fig.68 As shown, the performance of coil device 3010 is improved in the case where inner wall side surface 3032ca has inclined surface 3032s and outer wall side surface 3032cb does not have inclined surface 3032s.

[0769] Of course, if Fig.69 As shown, both the inner wall side surface 3032ca and the outer wall side surface 3032cb of the wall portion 3032 may have an inclined surface 3032s. In this case, both the inner groove side surface 3024ca and the outer groove side surface 3024cb of the groove 3024 may have an inclined surface 3024s. In addition, although not shown, both the inner mold side surface 3204ca and the outer mold side surface 3204cb of the mold 3202 may have an inclined surface 3204s.

[0770] In the above example, the inclined surfaces 3024s and 3032s of the groove 3024 and the wall portion 3032 extend from the height position of the first surface 3011A of the planar coil 3011 to the bottom 3024a or the top 3032a, but the present invention is not limited thereto. Figure 70 to Figure 72 In the illustrated example, the groove 3024 and the inclined surfaces 3024s and 3032s of the wall portion 3032 extend from a height position different from the height position of the first surface 3011A of the planar coil 3011 to the bottom 3024a or the top 3032a.

[0771] More specifically, in Figure 70 to Figure 72 In the example shown, the dimension of the base end portion 3032d of the wall portion 3032 along the axial direction of the coil is larger than the thickness of the planar coil 3011. That is, the base end portion 3032d protrudes toward the outer surface 3020S3 of the first retaining member 3020 further than the first surface 3011A of the planar coil 3011. It should be noted that, according to the findings obtained by the inventors, the greater the amount 3032dH by which the base end portion 3032d protrudes from the first surface 3011A of the planar coil 3011 toward the outer surface 3020S3 (hereinafter also referred to as "the protruding height 3032dH of the base end portion 3032d from the planar coil 3011"), the more the performance of the coil component 3010 is improved. Figure 61 to Figure 67 In the example shown, the protrusion height 3032dH of the base end portion 3032d from the planar coil 3011 is 0 mm. Figure 70 to Figure 72 In the illustrated example, a protrusion height 3032dH of the base end portion 3032d from the planar coil 3011 is greater than 0 mm. Figure 70 to Figure 72 The protrusion height 3032dH in the example shown is not particularly limited, but is preferably 1 mm or more from the viewpoint of effectively improving the performance of coil device 3010.

[0772] <Simulation of performance evaluation of coil parts>

[0773] Hereinafter, a description will be given of simulations performed for performance evaluation of the coil components of Examples 1 to 9 and Comparative Examples 1 to 5. The simulations were performed using Femtet (registered trademark) manufactured by Murata Software Co., Ltd.

[0774] The common conditions in the simulations of Examples 1 to 9 and Comparative Examples 1 to 5 are as follows.

[0775] · Coil parts 3010 include Figure 61 to Figure 64 The illustrated example includes a spirally formed planar coil 3011 , a first holding member 3020 , a second holding member 3030 , a first magnetic shield member 3040 , a second magnetic shield member 3050 , a first connection terminal 3061 , and a second connection terminal 3062 .

[0776] The coil component 3010 has a single planar coil 3011 .

[0777] The planar coil 3011 is wound into a substantially regular octagonal shape.

[0778] The planar coil 3011 has first to twelfth turn portions 301101 to 301112 .

[0779] The distance between adjacent turns 301101, 301102; 301111, 301112 is 3 mm. However, the distance between the inner end of the first turn 301101 in the coil radial direction and the inner end of the second turn 301102 in the coil radial direction is 6 mm.

[0780] The planar coil 3011 is formed of copper.

[0781] The line width of the planar coil 3011 is 7.5 mm and the thickness is 1.0 mm.

[0782] The diameter of the planar coil 3011 is 295 mm.

[0783] The first holding member 3020 is formed of glass fiber reinforced polyamide.

[0784] The width of the opening 3024b of the groove 3024 is 2.5 mm.

[0785] The second holding member 3030 is formed of a resin containing a magnetic body.

[0786] The relative magnetic permeability of the second holding member 3030 is 10.

[0787] The first magnetic shield 3040 is formed of a ferrite plate.

[0788] The relative magnetic permeability of the first magnetic shield 3040 is 3000.

[0789] The second magnetic shield 3050 is formed of aluminum.

[0790] The first connection terminal 3061 and the second connection terminal 3062 are connected to the inner end and the outer end of the planar coil 3011 in the coil radial direction.

[0791] The high-frequency current supplied to the planar coil 3011 is 40 A and the frequency is 85 kHz.

[0792] The common conditions in the simulations of Examples 1 to 9 are as follows.

[0793] At least one of the pair of wall side surfaces 3032ca and 3032cb of the wall portion 3032 has an inclined surface 3032s.

[0794] Individual conditions in Examples 1 to 9 and the simulations are as follows.

[0795] <Example 1>

[0796] The shapes of the wall portion 3032 and the groove 3024 are Fig.62 Shape shown.

[0797] The protrusion height 3032Ha of the wall portion 3032 from the planar coil 3011 is 2 mm.

[0798] The protrusion height 3032dH of the base end portion 3032d from the planar coil 3011 is 0 mm.

[0799] <Example 2>

[0800] The protrusion height 3032Ha of the wall portion 3032 from the planar coil 3011 is 4 mm.

[0801] The other conditions are the same as those in Example 1.

[0802] <Example 3>

[0803] The shapes of the wall portion 3032 and the groove 3024 are Fig.68 Shape shown.

[0804] The protrusion height 3032Ha of the wall portion 3032 from the planar coil 3011 is 2 mm.

[0805] The protrusion height 3032dH of the base end portion 3032d from the planar coil 3011 is 0 mm.

[0806] <Example 4>

[0807] The protrusion height 3032Ha of the wall portion 3032 from the planar coil 3011 is 4 mm.

[0808] The other conditions are the same as those in Example 3.

[0809] <Example 5>

[0810] The shapes of the wall portion 3032 and the groove 3024 are Fig.69 Shape shown.

[0811] The protrusion height 3032Ha of the wall portion 3032 from the planar coil 3011 is 2 mm.

[0812] The protrusion height 3032dH of the base end portion 3032d from the planar coil 3011 is 0 mm.

[0813] <Example 6>

[0814] The protrusion height 3032Ha of the wall portion 3032 from the planar coil 3011 is 4 mm.

[0815] The other conditions are the same as those in Example 5.

[0816] <Example 7>

[0817] The shapes of the wall portion 3032 and the groove 3024 are Fig.70 Shape shown.

[0818] The protrusion height 3032Ha of the wall portion 3032 from the planar coil 3011 is 4 mm.

[0819] The protrusion height 3032dH of the base end portion 3032d from the planar coil 3011 is 2 mm.

[0820] <Example 8>

[0821] The shapes of the wall portion 3032 and the groove 3024 are Fig.71 Shape shown.

[0822] The protrusion height 3032Ha of the wall portion 3032 from the planar coil 3011 is 4 mm.

[0823] The protrusion height 3032dH of the base end portion 3032d from the planar coil 3011 is 2 mm.

[0824] <Example 9>

[0825] The shapes of the wall portion 3032 and the groove 3024 are Fig.72 Shape shown.

[0826] The protrusion height 3032Ha of the wall portion 3032 from the planar coil 3011 is 4 mm.

[0827] The protrusion height 3032dH of the base end portion 3032d from the planar coil 3011 is 2 mm. The common conditions in the simulations of Comparative Examples 1 to 5 are as follows.

[0828] Neither of the pair of wall side surfaces 3032ca and 3032cb of the wall portion 3032 has the inclined surface 3032s. In other words, the wall portion 3032 is constituted by only the base end portion 3032d of the wall portion 3032 of Examples 1 to 9.

[0829] Individual conditions in the simulations of Comparative Examples 1 to 5 are as follows.

[0830] <Comparative Example 1>

[0831] The shapes of the wall portion 3032 and the groove 3024 are Fig.75 Shape shown.

[0832] The protrusion height 3032Ha of the wall portion 3032 from the planar coil 3011 is 0 mm.

[0833] <Comparative Example 2>

[0834] The protrusion height 3032Ha of the wall portion 3032 from the planar coil 3011 is 1 mm.

[0835] The other conditions were the same as those in Comparative Example 1.

[0836] <Comparative Example 3>

[0837] The protrusion height 3032Ha of the wall portion 3032 from the planar coil 3011 is 2 mm.

[0838] The other conditions were the same as those in Comparative Example 1.

[0839] <Comparative Example 4>

[0840] The protrusion height 3032Ha of the wall portion 3032 from the planar coil 3011 is 3 mm.

[0841] The other conditions were the same as those in Comparative Example 1.

[0842] <Comparative Example 5>

[0843] The protrusion height 3032Ha of the wall portion 3032 from the planar coil 3011 is 4 mm.

[0844] The other conditions were the same as those in Comparative Example 1.

[0845] <Evaluation>

[0846] exist Fig.73 and Fig.74 The simulation results are shown in . Fig.73 and Fig.74 Here, “Q value”, “L”, and “Z” refer to the Q value, inductance, and impedance of the coil component 3010 .

[0847] As from Fig.73 and Fig.74 It can be understood that the Q value of the coil component 3010 of Examples 1, 3, and 5 is equal to the Q value of the coil component of Comparative Example 2. Here, in Examples 1, 3, and 5, the protrusion height 3032dH of the base end portion 3032d from the plane coil 3011 is 0 mm. On the other hand, in Comparative Example 1, the protrusion height 3032H of the wall portion 3032 from the plane coil 3011 is 1 mm.

[0848] In addition, if Fig.73 and Fig.74 It can be understood that the Q value of the coil component 3010 of Examples 2, 4, and 6 is equal to the Q value of the coil component of Comparative Example 3. Here, in Examples 2, 4, and 6, the protrusion height 3032dH of the base end portion 3032d from the plane coil 3011 is 0 mm. On the other hand, in Comparative Example 2, the protrusion height 3032H of the wall portion 3032 from the plane coil 3011 is 2 mm.

[0849] In addition, if Fig.73 and Fig.74 It is understood that the Q value of the coil parts 3010 of Examples 7 to 9 is equal to the Q value of the coil parts of Comparative Example 4 or Comparative Example 5. Here, in Examples 7 to 9, the protruding height 3032dH of the base end portion 3032d from the plane coil 3011 is 2 mm. In contrast, in Comparative Examples 4 and 5, the protruding height 3032H of the wall portion 3032 from the plane coil 3011 is 3 mm and 4 mm, respectively. It should be noted that the width of the wall portion 3032 of Comparative Examples 4 and 5 is uniform in its protruding direction, and the protruding height 3032H from the plane coil 3011 is greater than 2 mm. Therefore, as described above, it is actually difficult to form the groove 3024 of the storage wall portion 3032 of Comparative Examples 4 and 5 on the first holding member 3020.

[0850] In addition, as can be understood by comparing Example 2 with Example 7, Example 4 with Example 8, and Example 6 with Example 9, the larger the protrusion height 3032dH of the base end portion 3032d from the planar coil 3011, the higher the Q value of the coil component 3010.

[0851] In addition, as can be understood by comparing Example 1 with Example 3, Example 2 with Example 4, and Example 7 with Example 8, in a case where only one of a pair of wall side surfaces 3032ca, 3032cb of the wall portion 3032 has the inclined surface 3032s, the Q value of the coil part 3010 tends to be improved in the case where the coil part 3010 including the inclined surface 3032s on the inner wall side surface 3032ca of the wall portion 3032 is compared to the coil part 3010 including the inclined surface 3032s on the outer wall side surface 3032cb of the wall portion 3032.

[0852] The coil component 3010 according to one embodiment described above includes a planar coil 3011, a first holding member 3020, and a second holding member 3030. The planar coil 3011 has a spiral shape and includes a first surface 3011A and a second surface 3011B on the opposite side of the first surface 3011A. The first holding member 3020 overlaps the planar coil 3011 in a manner opposite to the first surface 3011A and holds the planar coil 3011. The second holding member 3030 and the first holding member 3020 sandwich the planar coil 3011. The planar coil 3011 includes a plurality of turns 3011n arranged along the radial direction of the planar coil 3011, that is, the coil radial direction. The first holding member 3020 has a contact surface 3020S1 in contact with the first surface 3011A. A groove 3024 is formed on the contact surface 3020S1. When viewed in the axial direction of the planar coil 3011, i.e., in the axial direction of the coil, the slot 3024 extends between adjacent turns of the planar coil 3011. The second retaining member 3030 has a base 3031 and a wall 3032. The base 3031 contacts the second surface 3011B of the planar coil 3011. The wall 3032 extends from the base 3031 through between adjacent turns of the planar coil 3011 and into the slot 3024 of the first retaining member 3020. The width of the bottom 3024a of the slot 3024 is narrower than the width at the height position (the position in the axial direction of the coil) of the contact surface 3020S1 of the slot 3024. According to this coil component 3010, it is easy to deepen the depth of the slot 3024, and therefore, it is easy to increase the height of the wall 3032 and improve the performance of the coil component 3010. In addition, according to the coil device 3010, more material 3220 can remain between the groove 3024 of the first holding member 3020 and the outer surface 3020S3 of the first holding member 3020. Therefore, the strength reduction of the first holding member 3020 caused by forming the groove 3024 is suppressed, and the strength reduction of the coil device 3010 is also suppressed.

[0853] In addition, the manufacturing method of the coil component 3010 according to the embodiment described above includes: a step of preparing a mold 3202; a step of placing the planar coil 3011 in the mold 3202; a step of making a coil intermediate material 3010M; a step of removing the mold 3202 from the coil intermediate ma...

Claims

1. A coil component, comprising: A first planar coil including a plurality of turns arranged in a radial direction and a protruding piece extending from an inner periphery and / or an outer periphery of at least one of the plurality of turns and bent away from the turn; and a first holding member overlapping the first planar coil in a state of being in contact with the plurality of turn portions, The first holding member includes a groove on a surface overlapping the first planar coil, The protruding piece is in contact with the inner surface of the groove in the radial direction.

2. The coil component according to claim 1, wherein The turn portion is located outside the groove.

3. The coil component according to claim 2, wherein: The device further comprises a second holding member having magnetism and being integrated with the first planar coil and the first holding member so as to sandwich the first planar coil with the first holding member. The groove is filled with a portion of the second retaining member.

4. The coil component according to claim 3, wherein: A second planar coil is embedded in the second holding member, and the second planar coil is located at a position overlapping with the first planar coil. The second planar coil includes a plurality of turns arranged in a radial direction, and a protruding piece extending from an inner periphery and / or an outer periphery of at least one of the plurality of turns and bent away from the turn of the second planar coil. The protruding piece of the second planar coil is in contact with the second holding member in the radial direction.

5. The coil component according to claim 4, wherein: The first holding member further includes a protrusion, the protrusion protruding from the groove and embedded in the second holding member, The protrusion portion faces the protruding piece of the second planar coil in the radial direction.

6. The coil component according to claim 5, wherein: The first retaining component further includes a spacer portion on at least any one of the portion between the groove on the surface overlapping the first planar coil and the turn portion on the inner side of the groove in the radial direction, and the portion between the groove and the turn portion on the outer side of the groove in the radial direction, wherein the spacer portion protrudes away from the first planar coil and is adjacent to the protrusion in the radial direction.

7. The coil component according to any one of claims 1 to 6, wherein The groove extends in a spiral shape along the plurality of turns.

8. The coil component according to any one of claims 1 to 7, wherein The groove includes a recessed portion, At least a portion of the protruding piece is located in the recessed portion.

9. The coil component according to any one of claims 1 to 8, wherein The protruding piece extends from the inner peripheral edge and the outer peripheral edge of the turn portion, respectively.

10. The coil component according to any one of claims 1 to 8, wherein The protruding piece extends only from the outer peripheral edge of the turn portion.

11. The coil component according to any one of claims 1 to 10, wherein The turn portion connected to the protruding piece has a through hole at a position adjacent to the protruding piece in the radial direction.

12. A method for manufacturing a coil component, comprising: A step of preparing a coil intermediate material, the coil intermediate material including a plurality of turns arranged in a radial direction and a connecting portion connecting the turns adjacent to each other in the radial direction; A step of preparing a mold having a convex portion formed thereon; A step of placing the coil intermediate material in the mold so that the connecting portion faces the convex portion and the adjacent turn portions connected by the connecting portion face a portion of the mold different from the convex portion; A step of pushing a forming material into the die via the coil intermediate material, and relatively pressing the convex portion into the forming material via the connecting portion, thereby separating the connecting portion from any one of the adjacent turn portions, and bending the connecting portion away from the turn portion, and forming a groove in the forming material; and A step of removing the molding material from the mold after solidifying the molding material.

13. The method for manufacturing a coil component according to claim 12, wherein: The mold has a positioning protrusion rising from a portion different from the convex portion, The turn portion connected to the connecting portion has a through hole at a position adjacent to the connecting portion in the radial direction, The coil intermediate material is placed in the die in a state where the positioning protrusion passes through the through hole.

14. The method for manufacturing a coil component according to claim 12 or 13, wherein: The connecting portion has a narrowed portion where a cross-sectional area is locally reduced.

15. The method for manufacturing a coil component according to claim 14, wherein: The narrow portion is formed at a middle position of the connecting portion in the radial direction.

16. The method for manufacturing a coil component according to claim 14, wherein: The narrow portion is formed at an outer end portion of the connecting portion in the radial direction.

17. A method for manufacturing a coil component, comprising: A step of preparing a preliminary coil component, the preliminary coil component comprising a first planar coil including a plurality of turns arranged in a radial direction, and a first holding member overlapping the first planar coil in a state of being in contact with the plurality of turns, the first holding member including a groove on a surface overlapping the first planar coil, the groove being formed to be open between adjacent turns, and the first holding member further including a protrusion protruding from the groove; a step of preparing a second coil intermediate material, the second coil intermediate material including a plurality of turns arranged in the radial direction and a connecting portion connecting the turns adjacent to each other in the radial direction; a step of overlapping the second coil intermediate material with the first planar coil in such a manner that the connecting portion faces the protruding portion; and A step of pressing the connection portion against the protrusion to separate the connection portion from any one of the adjacent turn portions connected to the connection portion and to bend the connection portion away from the turn portion. 18 . A power transmission device comprising the coil component according to claim 1 . 19 . A power receiving device comprising the coil component according to claim 1 .

20. A power transmission system comprising a power transmission device and a power receiving device, At least one of the power transmitting device and the power receiving device includes the coil component according to any one of claims 1 to 11. 21 . A movable body comprising the coil component according to claim 1 .

22. A coil component, comprising: A planar coil having a spiral shape, comprising a first surface and a second surface extending on a central axis of the spiral shape and opposite to each other in the axial direction; and a first holding member which overlaps the planar coil so as to face the second surface and holds the planar coil; A through hole is formed on the planar coil, penetrating from the first surface to the second surface. The first retaining component includes: a base portion, which includes a contact surface connected to the second surface and extending along the second surface; and a rib portion, which protrudes from the contact surface and passes through the through hole, and is in contact with or close to the inner circumferential surface of the through hole in a radial direction of the planar coil orthogonal to the center axis.

23. The coil component according to claim 22, wherein: The first retaining member includes a plurality of ribs, The plurality of ribs are arranged side by side at intervals in the radial direction.

24. The coil component according to claim 22 or 23, wherein: The rib includes: a raised portion that contacts or approaches the through hole in the radial direction and passes over the planar coil in the axial direction; and an overhang portion that extends from the raised portion in the radial direction and is opposite to the first surface.

25. A coil component, comprising: A planar coil having a spiral shape, comprising a first surface and a second surface extending on a central axis of the spiral shape and opposite to each other in the axial direction; and a first holding member which overlaps the planar coil so as to face the second surface and holds the planar coil; The first holding member includes: a base portion including a contact surface that is in contact with the second surface and extends along the second surface; and a rib portion that protrudes from the contact surface and contacts or approaches a side surface of the planar coil located between the first surface and the second surface in a radial direction of the planar coil orthogonal to the central axis. The rib includes: a raised portion that contacts or approaches the side surface of the planar coil in the radial direction and passes over the planar coil in the axial direction; and an overhang portion that extends from the raised portion in the radial direction and is opposite to the first surface.

26. The coil component according to claim 25, wherein The raised portion extends in a spiral shape along the spiral-shaped planar coil.

27. The coil component according to claim 25 or 26, wherein: The raised portion includes: an inner raised portion that contacts or approaches an inner peripheral side surface of the side surface facing the central axis in the radial direction; and an outer raised portion that contacts or approaches an outer peripheral side surface located on the side surface opposite to the inner peripheral side surface. The inner raised portion and the outer raised portion respectively protrude from the contact surface in a state of being separated in the radial direction.

28. The coil component according to any one of claims 25 to 27, wherein The rib comprises a plurality of overhanging portions, The plurality of overhanging portions are disposed at intervals in a direction in which the planar coil extends in a spiral shape.

29. The coil component according to claim 28, wherein The plurality of overhanging portions are disposed side by side at intervals in the radial direction or in a direction parallel to the radial direction.

30. The coil component according to any one of claims 25 to 29, wherein The overhanging portion partially covers the first surface.

31. The coil component according to claim 30, wherein The overhang portion covers a range less than 25% of the area of ​​the first surface.

32. The coil component according to any one of claims 22 to 31, wherein The first holding member is non-magnetic and insulating.

33. The coil component according to any one of claims 22 to 32, wherein The invention further includes a second holding member having magnetism and being integrated with the planar coil and the first holding member so as to sandwich the planar coil with the first holding member.

34. The coil component according to claim 33, wherein The planar coil comprises a plurality of turns arranged along the radial direction. The first retaining member forms a groove at a portion of the contact surface located between adjacent turns. The second holding member fills the interior of the groove.

35. The coil component according to claim 29, wherein further comprising a first magnetic shielding member, the first magnetic shielding member being arranged to face the first surface of the planar coil, The first magnetic shielding member includes a plurality of magnetic plates having magnetism. The plurality of magnetic plates include two magnetic plates, and the two magnetic plates are arranged to sandwich the plurality of overhanging portions that are arranged side by side at intervals in the radial direction.

36. The coil component according to any one of claims 22 to 35, wherein The invention further includes an adhesive layer containing a thermoplastic resin for bonding the second surface and the contact surface.

37. The coil component according to any one of claims 22 to 36, wherein The surface roughness of the second surface is greater than the surface roughness of the first surface.

38. A method for manufacturing a coil component, comprising: A step of preparing a mold having a concave portion formed therein; A step of preparing a planar coil having a spiral shape and including a first surface and a second surface extending on a central axis of the spiral shape and opposite to each other in an axial direction; A step of placing the planar coil in the mold in a state where the first surface faces the surface of the mold on which the recess is formed and the planar coil partially covers the recess; and A step of providing a molding material in a manner covering the second surface, forming a portion filling the recess and a portion covering the second surface with the molding material, and solidifying the molding material in a state where the portion filling the recess and the portion covering the second surface are connected.

39. The method for manufacturing a coil component according to claim 38, wherein: A through hole is formed on the planar coil, penetrating from the first surface to the second surface. The planar coil is placed in the mold in a state where the through hole overlaps the recessed portion, and the molding material is filled from the through hole into the recessed portion.

40. The method for manufacturing a coil component according to claim 38 or 39, wherein: The planar coil is placed in the mold in a state where it partially covers the recessed portion. The molding material is filled into the recess from a portion of the recess that is not covered by the planar coil.

41. The method for manufacturing a coil component according to claim 40, wherein: A support portion is provided in the mold, and the support portion is formed to be located inside the recessed portion, The planar coil is placed in the mold such that a portion of the planar coil covering the recessed portion overlaps the supporting portion.

42. A method for manufacturing a coil component, comprising: The process of preparing the mold; A step of preparing a planar coil having a spiral shape, including a first surface and a second surface extending on a central axis of the spiral shape and opposite to each other in the axial direction, and having a through hole penetrating from the first surface to the second surface; a step of placing the planar coil in the mold; and The step of providing a molding material so as to cover the second surface, forming a portion filling the through hole and a portion covering the second surface with the molding material, and solidifying the molding material in a state where the portion filling the through hole and the portion covering the second surface are connected.

43. A coil intermediate material, comprising: A planar coil having a spiral shape, comprising a first surface and a second surface extending on a central axis of the spiral shape and opposite to each other in the axial direction; and a first holding member which overlaps the planar coil so as to face the second surface and holds the planar coil; A through hole is formed on the planar coil, penetrating from the first surface to the second surface. The first retaining component includes: a base portion, which includes a contact surface connected to the second surface and extending along the second surface; and a rib portion, which protrudes from the contact surface and passes through the through hole, and is in contact with or close to the inner circumferential surface of the through hole in a radial direction of the planar coil orthogonal to the center axis.

44. A coil intermediate material, comprising: A planar coil having a spiral shape, comprising a first surface and a second surface extending on a central axis of the spiral shape and opposite to each other in the axial direction; and a first holding member which overlaps the planar coil so as to face the second surface and holds the planar coil; The first holding member includes: a base portion including a contact surface that is in contact with the second surface and extends along the second surface; and a rib portion that protrudes from the contact surface and contacts or approaches a side surface of the planar coil located between the first surface and the second surface in a radial direction of the planar coil orthogonal to the central axis. The rib includes: a raised portion that contacts or approaches the side surface of the planar coil in the radial direction and passes over the planar coil in the axial direction; and an overhang portion that extends from the raised portion in the radial direction and is opposite to the first surface.

45. A power transmission device comprising the coil component according to any one of claims 22 to 37.

46. ​​A power receiving device comprising the coil component according to any one of claims 22 to 37.

47. A power transmission system comprising a power transmission device and a power receiving device, At least one of the power transmitting device and the power receiving device includes the coil component according to any one of claims 22 to 37.

48. A movable body comprising the coil component according to any one of claims 22 to 37.

49. A coil component, comprising: A planar coil having a spiral shape, comprising a first surface and a second surface extending on a central axis of the spiral shape and opposite to each other in the axial direction; a first holding member overlapping the planar coil in a manner opposite to the second surface and holding the planar coil; as well as a second holding member which is integrated with the planar coil and the first holding member in such a manner as to sandwich the planar coil with the first holding member; The planar coil includes a plurality of turns arranged along a radial direction of the planar coil. The second holding member has a protrusion extending along the axial direction between adjacent turns of the planar coil. The first holding member has a contact surface that contacts the second surface and an outer surface on a side opposite to the contact surface. A first groove for accommodating the protrusion is formed on the contact surface, A second groove is formed on the outer surface, The second groove is formed in a region of the outer surface overlapping with a region on the contact surface including the center axis and the first groove when viewed in the axial direction.

50. The coil component according to claim 49, wherein The second groove is formed along the spiral shape of the planar coil when viewed in the axial direction.

51. The coil component according to claim 49 or 50, wherein: The width of the second groove is 0.2 to 1.1 times the width of the first groove.

52. The coil component according to any one of claims 49 to 51, wherein The depth of the second groove is 0.2 to 1.1 times the depth of the first groove.

53. The coil component according to any one of claims 49 to 52, wherein The volume of the second groove is 0.2 to 1.1 times the volume of the first groove.

54. The coil component according to any one of claims 49 to 53, wherein Viewed in the axial direction, the second groove does not overlap with the first groove.

55. A coil component, comprising: A planar coil having a spiral shape, comprising a first surface and a second surface extending on a central axis of the spiral shape and opposite to each other in the axial direction; a first holding member overlapping the planar coil in a manner opposite to the second surface and holding the planar coil; as well as a second holding member which is integrated with the planar coil and the first holding member in such a manner as to sandwich the planar coil with the first holding member; The planar coil includes a plurality of turns arranged along a radial direction of the planar coil. The second holding member has a protrusion extending along the axial direction between adjacent turns of the planar coil. The first holding member has a contact surface that contacts the second surface and an outer surface on a side opposite to the contact surface. A first groove for accommodating the protrusion is formed on the contact surface, At least one rib is formed on the outer surface, The at least one rib is formed on a region of the outer surface overlapping with a region on the contact surface including the central axis and the first groove when viewed in the axial direction.

56. The coil component according to claim 55, wherein The at least one rib includes a plurality of ribs extending in directions intersecting each other.

57. The coil component according to claim 55 or 56, wherein: The at least one rib comprises a plurality of ribs, The plurality of ribs are formed in a lattice shape when viewed in the axial direction.

58. The coil component according to any one of claims 49 to 57, wherein The first holding member is non-magnetic and insulating.

59. The coil component according to any one of claims 49 to 58, wherein The second holding member has magnetism.

60. The coil component according to any one of claims 49 to 59, wherein The planar coil is formed in a plate shape.

61. The coil component according to any one of claims 49 to 59, wherein The planar coil is formed using litz wires.

62. A coil intermediate material, comprising: A planar coil having a spiral shape, comprising a first surface and a second surface extending on a central axis of the spiral shape and opposite to each other in the axial direction; and a first holding member which overlaps the planar coil so as to face the second surface and holds the planar coil; The planar coil includes a plurality of turns arranged along a radial direction of the planar coil. The first holding member has a contact surface that contacts the second surface and an outer surface on a side opposite to the contact surface. A first groove is formed on the contact surface, A second groove is formed on the outer surface, When viewed in the axial direction, the first groove is formed between adjacent turns of the planar coil along the spiral shape of the planar coil. The second groove is formed in a region of the outer surface overlapping with a region on the contact surface including the center axis and the first groove when viewed in the axial direction.

63. The coil intermediate material according to claim 62, wherein: The second groove is formed along the spiral shape of the planar coil when viewed in the axial direction.

64. A coil intermediate material, comprising: A planar coil having a spiral shape, comprising a first surface and a second surface extending on a central axis of the spiral shape and opposite to each other in the axial direction; and a first holding member which overlaps the planar coil so as to face the second surface and holds the planar coil; The planar coil includes a plurality of turns arranged along a radial direction of the planar coil. The first holding member has a contact surface that contacts the second surface and an outer surface on a side opposite to the contact surface. A first groove is formed on the contact surface, At least one rib is formed on the outer surface, When viewed in the axial direction, the first groove is formed between adjacent turns of the planar coil along the spiral shape of the planar coil. The at least one rib is formed on a region of the outer surface overlapping with a region on the contact surface including the central axis and the first groove when viewed in the axial direction.

65. The coil intermediate material according to claim 64, wherein: The at least one rib includes a plurality of ribs extending in directions intersecting each other.

66. A power transmission device comprising the coil component according to any one of claims 49 to 61.

67. A power receiving device comprising the coil component according to any one of claims 49 to 61.

68. A power transmission system comprising a power transmission device and a power receiving device, At least one of the power transmitting device and the power receiving device includes the coil component according to any one of claims 49 to 61.

69. A movable body comprising the coil component according to any one of claims 49 to 61.

70. A coil component, comprising: A planar coil having a spiral shape, comprising a first surface and a second surface opposite to the first surface; a first holding member overlapping the planar coil so as to face the first surface and holding the planar coil; and a second holding member, which clamps the planar coil together with the first holding member, The planar coil comprises a plurality of turns arranged along the radial direction of the planar coil, that is, along the radial direction of the coil. The first holding member has a contact surface that contacts the first surface. A groove is formed on the contact surface, and when viewed in the axial direction of the planar coil, that is, in the axial direction of the coil, the groove extends between adjacent turns of the planar coil. The second holding member includes a base portion contacting the second surface of the planar coil, and a wall portion extending from the base portion through between adjacent turns of the planar coil and into the groove of the first holding member. The width of the bottom of the groove is narrower than the width of the groove at a height position of the contact surface.

71. The coil component according to claim 70, wherein The surface of the first holding member that defines the slot has a pair of slot side surfaces that face each other in the radial direction of the coil. At least one of the pair of slot side surfaces has an inclined surface inclined with respect to the coil axial direction.

72. The coil component according to claim 71, wherein The slot side surface located on the outer side in the radial direction of the coil among the pair of slot side surfaces has the inclined surface.

73. The coil component according to claim 71, wherein The slot side surface located on the inner side in the radial direction of the coil among the pair of slot side surfaces has the inclined surface.

74. The coil component according to claim 71, wherein The pair of slot side surfaces each have an inclined surface inclined with respect to the coil axial direction.

75. The coil component according to any one of claims 70 to 74, wherein The wall portion has a base end portion extending from the base portion along the coil axial direction with a uniform width. A dimension of the base end portion along the coil axial direction is larger than a thickness of the planar coil.

76. The coil component according to any one of claims 70 to 75, wherein The distance between the top of the groove and the contact surface is greater than 2 mm.

77. The coil component according to any one of claims 70 to 76, wherein The width of the bottom of the groove is less than or equal to one-half of the width of the groove at a height position of the contact surface.

78. The coil component according to any one of claims 70 to 77, wherein The first retaining member comprises fibers.

79. The coil component according to any one of claims 70 to 78, wherein The first holding member is non-magnetic and insulating.

80. The coil component according to any one of claims 70 to 79, wherein The second holding member has magnetism.

81. The coil component according to any one of claims 70 to 80, wherein The planar coil is formed in a plate shape.

82. A power transmission device comprising the coil component according to any one of claims 70 to 81.

83. A power receiving device comprising the coil component according to any one of claims 70 to 81.

84. A power transmission system comprising a power transmission device and a power receiving device, At least one of the power transmitting device and the power receiving device includes the coil component according to any one of claims 70 to 81.

85. A movable body comprising the coil component according to any one of claims 70 to 81.

86. A method for manufacturing the coil component according to any one of claims 70 to 81, the method comprising: a step of preparing a mold having a main body and a spiral-shaped protrusion extending from the main body; a step of arranging a spiral-shaped planar coil corresponding to the spiral shape of the convex portion in the main body of the mold so that the convex portion protrudes from between adjacent turns of the planar coil; A step of forming a first holding member by pressing a material for making a first holding member in a mold in which the planar coil is arranged, thereby making a coil intermediate material in which the first holding member and the planar coil are integrated; a step of removing the mold from the coil intermediate material; and After removing the mold from the coil intermediate material, a second holding body covering the planar coil is formed on the coil intermediate material. The width of the top of the convex portion of the mold is narrower than the width of the convex portion at a connection position with the main body portion.

87. The manufacturing method according to claim 86, wherein: The convex portion has a pair of mold side surfaces facing each other in the radial direction of the convex portion, that is, in the radial direction of the mold, At least one of the pair of mold side surfaces has an inclined surface inclined with respect to the axial direction of the protrusion, that is, the mold axial direction.

88. The manufacturing method according to claim 87, wherein: The mold side surface located on the outer side in the mold radial direction of the pair of mold side surfaces has an inclined surface inclined with respect to the mold axial direction.

89. The manufacturing method according to claim 87, wherein: The mold side surface located on the inner side in the mold radial direction of the pair of mold side surfaces has an inclined surface inclined with respect to the mold axial direction.

90. The manufacturing method according to claim 87, wherein: The pair of mold side surfaces each have an inclined surface inclined relative to the mold axial direction.

91. The method according to any one of claims 86 to 90, wherein: The width of the top of the convex portion is less than or equal to one half of the width of the convex portion at a connection position with the main body portion.

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