Coil forming member

Abstract

The invention provides a coil forming member. A coil forming member (10) is provided with a base guide (13), a corner guide (17), and a guide frame (21). The base guide (13) winds the electric wire (11) in a first turn when the electric wire (11) is disposed in a scroll shape about the central axis (O). The corner guide (17) supports, at least from the outside side, the bent portion of the nth turn of the electric wire (11), where n is an arbitrary natural number. The guide frame (21) supports the outermost corner guide (17) from the outer side. A second basic claw portion (13d) of the basic guide (13), a claw portion (25a) of the corner guide (17), and a claw holding portion (25b) connect the basic guide (13) and the innermost corner guide (17) through a so-called cantilever-type buckle, and connect adjacent corner guides (17) to each other.

Description

Technical Field

[0001] The present invention relates to a coil forming member. Background Art

[0002] In recent years, more people are conducting research and development related to charging and power supply in vehicles equipped with secondary batteries, which contributes to the efficiency of energy, in order to ensure the use of convenient, reliable, sustainable, and advanced energy.

[0003] Conventionally, in a non-contact power transmission system that supplies power from the outside of a vehicle to the vehicle by non-contact power transmission, in a power transmission device and a power reception device, a planar coil that has a gap between windings and is formed in a spiral shape in a planar manner is known (for example, refer to Japanese Patent Application Laid-Open No. 2020-13810). Conventionally, when a gap is provided between windings, a method of inserting a winding into a guide groove formed in a support substrate or a method of providing a spacer between windings is known (for example, refer to Japanese Patent Application Laid-Open No. 6-333755). Summary of the Invention

[0004] In technologies related to charging and power supply in vehicles equipped with secondary batteries, it is desired to suppress the skew and deformation of windings provided in a power transmission device and a power reception device, and to improve the ease of a coil forming process for maintaining a prescribed interval between windings. For example, when a plurality of spacers are provided between spiral windings such as the planar coil of the above-described prior art, there is a problem that it is difficult to improve the ease of coil forming due to, for example, the deviation of the positions of the plurality of spacers.

[0005] An object of a solution of the present invention is to provide a coil forming member that can improve the ease of coil forming. Further, a solution of the present invention contributes to the efficiency of energy.

[0006] A coil forming member according to an aspect of the present invention includes: a first guide member around which a wire is wound in a first turn when the wire is arranged in a spiral shape around a prescribed axis; a second guide member that supports at least a bent portion of the wire in an n-th turn from an outer side, where n is an arbitrary natural number; a third guide member that supports the outermost second guide member from an outer side; and a plurality of connecting members that connect the first guide member to the innermost second guide member and connect adjacent second guide members to each other.

[0007] In a second aspect, based on the coil forming member described in the first aspect above, it is also possible that a plurality of the connecting members are used as first connecting members, and the coil forming member includes: a fourth guiding member that supports at least a straight portion of the wire of the n-th turn from the outer side; and a plurality of second connecting members that connect the first guiding member and the innermost fourth guiding member and connect adjacent fourth guiding members to each other.

[0008] In a third aspect, based on the coil forming member described in the first or second aspect above, it is also possible that the first guiding member includes a first fixing portion for fixing a winding start portion of the wire, and the third guiding member includes a second fixing portion for fixing a winding end portion of the wire.

[0009] In a fourth aspect, based on the coil forming member described in the third aspect above, it is also possible that the first guiding member includes a displacement portion for displacing a coiling position of the wire of the first turn to the outer side, and the coil forming member includes: a fifth guiding member that displaces a coiling position of the wire of the (n + 1)-th turn to the outer side; and a plurality of third connecting members that connect the displacement portion and the innermost fifth guiding member and connect adjacent fifth guiding members to each other.

[0010] According to the first aspect above, there are provided a plurality of connecting members that connect the first guiding member and the plurality of second guiding members, whereby it is possible to suppress skew and deformation of a bent portion of the wire and improve the ease of a coil forming process of maintaining an interval between wires at a specified interval.

[0011] By adding a second guiding member that supports the bent portion from the outer side when the wire is arranged in a spiral shape, it is possible to maintain the position in the axial direction of the wire as constant and suppress skew and deformation of the wire.

[0012] There is provided a third guiding member that supports the outermost second guiding member from the outer side, whereby even if the shape of the wire is, for example, a flat shape that is easily deformable, deformation during handling or the like can be suppressed.

[0013] In the case of the second aspect above, there are provided a plurality of second connecting members that connect the first guiding member and the plurality of fourth guiding members, whereby it is possible to suppress skew and deformation of a straight portion of the wire and improve the ease of a coil forming process of maintaining an interval between wires at a specified interval.

[0014] In the case of the third aspect above, there are provided a first fixing portion and a second fixing portion, whereby deformation when the wire is arranged in a spiral shape can be suppressed.

[0015] In the case of the fourth aspect described above, there are provided a plurality of third connecting members that connect the displacement portion of the first guiding member to the plurality of fifth guiding members, whereby it is possible to suppress the skew and deformation at the portion where the coiling position of the electric wire is displaced outward, and improve the ease of the coil forming process of maintaining the interval between electric wires at a specified interval. BRIEF DESCRIPTION OF THE DRAWINGS

[0016] Figure 1 FIG. 1 is a perspective view showing the structure of a coil forming member in an embodiment of the present invention.

[0017] Figure 2 FIG. 2 is a plan view of the coil forming member according to the embodiment of the present invention, as viewed along the axial direction of the central axis.

[0018] Figure 3 FIG. 3 is a perspective view showing the winding start fixing portion of the base guide in the coil forming member according to the embodiment of the present invention.

[0019] Figure 4 FIG. 4 is a perspective view showing the winding end fixing portion of the guide frame and the structure of the displacement guide in the coil forming member according to the embodiment of the present invention.

[0020] Figure 5 FIG. 5 is a perspective view showing the corner guide in the coil forming member according to the embodiment of the present invention.

[0021] Figure 6 FIG. 6 is a perspective view showing a part of each of the base guide, the guide frame, and the corner guide in the coil forming member according to the embodiment of the present invention, with a cutaway view.

[0022] Figure 7 FIG. 7 is a plan view of the corner guide in the coil forming member according to the embodiment of the present invention, as viewed along the axial direction of the central axis.

[0023] Figure 8 FIG. 8 is a perspective view showing the straight guide in the coil forming member according to the embodiment of the present invention.

[0024] Figure 9 FIG. 9 is a diagram schematically showing the coil forming process of the coil forming member based on the embodiment of the present invention. DETAILED DESCRIPTION OF THE INVENTION

[0025] Hereinafter, a coil forming member according to an embodiment of the present invention will be described with reference to the drawings.

[0026] Figure 1 FIG. 1 is a perspective view showing the structure of the coil forming member 10 of the embodiment. Figure 2 FIG. 2 is a plan view of the coil forming member 10 of the embodiment, as viewed along the axial direction of the central axis O.

[0027] The coil forming member 10 of the embodiment is used for forming the coil C included in at least one of a power transmission device and a power reception device of a non-contact power transmission system that supplies power to a moving body such as a vehicle from the outside of the moving body by non-contact power transmission. The vehicle is, for example, an electric vehicle such as a motor vehicle, a hybrid vehicle, and a fuel cell vehicle.

[0028] As Figure 1 and Figure 2 shown, the coil C of the embodiment is formed, for example, by arranging a wire 11 such as a flat copper wire around a central axis (prescribed axis) O in a rounded rectangular spiral shape by using the coil forming member 10.

[0029] The coil forming member 10 of the embodiment includes, for example, a base guide 13 (first guide member), a plurality of displacement guides 15 (fifth guide members), a plurality of corner guides 17 (second guide members), a plurality of straight guides 19 (fourth guide members), and a guide frame 21 (third guide member).

[0030] The outer shape of the base guide 13 is, for example, a rounded rectangular frame shape. The base guide 13 has an outer peripheral surface 13A around which the wire 11 of the first turn in the spiral coil C is wound.

[0031] Figure 3 is a perspective view showing a winding start fixing portion 13a (first fixing portion) of the base guide 13 in the coil forming member 10 of the embodiment.

[0032] As Figure 3 shown, the base guide 13 has, for example, at a prescribed position on the outer peripheral portion, a winding start fixing portion 13a that fixes the winding start portion 11a of the wire 11. The prescribed position on the outer peripheral portion is, for example, a linear portion such as a linear portion other than a curved corner portion. The winding start portion 11a of the wire 11 is, for example, a portion where the wire 11 is bent in the thickness direction and then folded back in the width direction.

[0033] In the winding start fixing portion 13a, for example, a groove that penetrates the base guide 13 in the axial direction along the prescribed axis O and in which the winding start portion 11a of the wire 11 is assembled is formed.

[0034] As Figure 1 and Figure 2As shown, the base guide 13 has a displacement portion 13b, which is provided, for example, at a position deviated in the winding direction of the electric wire 11 along the outer peripheral portion from the winding start fixing portion 13a. The displacement portion 13b bulges outward, for example, in the direction orthogonal to the outer peripheral portion, thereby increasing the thickness of the base guide 13. The surface (outer surface) of the displacement portion 13b, which is a part of the outer peripheral surface 13A, is, for example, a curved surface that smoothly changes from a concave curved surface shape to a convex curved surface shape along the winding direction. The displacement portion 13b displaces the winding start position of the first turn of the electric wire 11 to the outer side, thereby staggering the winding start position of the second turn of the electric wire 11 to the outer side (the winding increase side of the coil C, i.e., the outer side) compared to the winding start position of the first turn of the electric wire 11.

[0035] Figure 4 FIG. is a perspective view showing the structure of the winding end fixing portion 21b (second fixing portion) of the guide frame 21 and the displacement guide 15 in the coil forming member 10 of the embodiment.

[0036] As Figure 1 , Figure 2 and Figure 4 shown, the outer shape of each of the plurality of displacement guides 15 is, for example, a plate shape bent in an S shape. The two surfaces in the thickness direction of each displacement guide 15 are, for example, a curved surface corresponding to the outer surface of the displacement portion 13b in contact therewith and a curved surface having the same shape as the outer surface of the displacement portion 13b. The plurality of displacement guides 15 are arranged, for example, in a stacked manner in sequence outward from the displacement portion 13b of the base guide 13. The innermost displacement guide 15 and the displacement portion 13b of the base guide 13 sandwich the first turn of the electric wire 11 from both sides in the thickness direction.

[0037] The displacement guides 15 adjacent to each other in the arrangement direction sandwich the (n + 1)-th turn of the electric wire 11 from both sides in the thickness direction (n is an arbitrary natural number). Each displacement guide 15 displaces the winding start position of the (n + 1)-th turn of the electric wire 11 to the outer side, thereby staggering the winding start position of the (n + 2)-th turn of the electric wire 11 to the outer side (the winding increase side of the coil C, i.e., the outer side) compared to the winding start position of the (n + 1)-th turn of the electric wire 11.

[0038] Each displacement guide 15 includes, for example, a pair of claw portions 23a (third connecting members) and claw holding portions 23b (third connecting members) provided on both sides in the axial direction along a specified axis O. Each claw holding portion 23b of the innermost displacement guide 15 is mechanically engaged with each first base claw portion 13c (third connecting member) of the displacement portion 13b of the base guide 13 by a so-called cantilever type snap. Each first base claw portion 13c is a pair of first base claw portions 13c provided on both sides of the displacement portion 13b in the axial direction along the specified axis O. Among the displacement guides 15 adjacent to each other in the arrangement direction, each claw holding portion 23b of the outer displacement guide 15 is mechanically engaged with each claw portion 23a of the inner displacement guide 15 by a so-called cantilever type snap. For example, a through hole into which each first base claw portion 13c or each claw portion 23a is inserted is formed in each claw holding portion 23b. Each claw holding portion 23b engages with each first base claw portion 13c or each claw portion 23a inserted into the through hole by elastic deformation of the front end portion, thereby fixing the innermost displacement guide 15 and the displacement portion 13b of the base guide 13 to each other and fixing the displacement guides 15 adjacent to each other in the arrangement direction to each other. The outermost displacement guide 15 is supported, for example, by the inner peripheral surface 21A of the guide frame 21 and the convex portion 21a protruding inward from the inner peripheral surface 21A from at least one of the outer side and the axial direction side.

[0039] Figure 5 FIG. 4 is a perspective view of the corner guide 17 in the coil forming member 10 according to the embodiment.

[0040] Figure 6 FIG. 5 is a perspective view showing a cutaway portion of a part of the base guide 13, the guide frame 21, and the corner guide 17 in the coil forming member 10 according to the embodiment. Figure 7 FIG. 6 is a plan view of the corner guide 17 in the coil forming member 10 according to the embodiment as viewed from the axial direction along the central axis O.

[0041] As Figure 1 , Figure 2 , Figure 5 , Figure 6 and Figure 7As shown, the outer shapes of the plurality of corner guides 17 are each, for example, a plate shape bent into a U shape. For example, both surfaces in the thickness direction of each corner guide 17 are provided with a curved surface having a shape corresponding to be in contact with the outer peripheral surfaces 13A of the four corners of the base guide 13 and a curved surface having the same shape as the outer peripheral surfaces 13A of the respective corners. The plurality of corner guides 17 are arranged, for example, in a manner of being sequentially arranged and stacked outward from each corner of the base guide 13. The innermost corner guide 17 at each corner and each corner of the base guide 13 sandwich the first turn of the electric wire 11 from both sides in the thickness direction. The adjacent corner guides 17 in the arrangement direction sandwich the (n + 1)-th turn of the electric wire 11 from both sides in the thickness direction (n is an arbitrary natural number). Each corner guide 17 forms a bent portion of the electric wire 11, for example, by bending the (n + 1)-th turn of the electric wire 11 along the outer peripheral surface 13A of each corner of the base guide 13.

[0042] Each corner guide 17 is provided with, for example, a pair of claw portions 25a (connecting members, first connecting members) and claw holding portions 25b (connecting members, first connecting members) provided on both surfaces in the axial direction along a predetermined axis O. The claw holding portion 25b of the innermost corner guide 17 at each corner is mechanically engaged with each second base claw portion 13d (connecting member, first connecting member) of each corner of the base guide 13 by a so-called cantilever type snap fit. Each second base claw portion 13d is a pair of second base claw portions 13d provided on both surfaces of each corner in the axial direction along a predetermined axis O. Among the adjacent corner guides 17 in the arrangement direction, the claw holding portions 25b of the outer corner guide 17 are mechanically engaged with the claw portions 25a of the inner corner guide 17 by a so-called cantilever type snap fit. A through hole for inserting each second base claw portion 13d or each claw portion 25a is formed, for example, in each claw holding portion 25b. Each claw holding portion 25b meshes the front end portion with each second base claw portion 13d or each claw portion 25a inserted into the through hole by elasticity, thereby fixing the innermost corner guide 17 at each corner and each corner of the base guide 13 to each other and fixing the adjacent corner guides 17 in the arrangement direction to each other. The outermost corner guide 17 at each corner is supported, for example, by the inner peripheral surface 21A of the guide frame 21 and the convex portion 21a protruding inward from the inner peripheral surface 21A from at least one side of the outer side and the axial direction.

[0043] As Figure 7 shown, each corner guide 17 is provided with, for example, a bent plate-shaped portion 17a and two straight plate-shaped portions 17b provided at both ends of the bent plate-shaped portion 17a. For example, the bent plate-shaped portion 17a bends the electric wire 11 along an arc of a predetermined central angle such as 90°. For example, the two straight plate-shaped portions 17b cause the electric wire 11 to linearly advance along directions intersecting each other at a predetermined angle such as 90°.

[0044] Figure 8 is a perspective view of the linear guide 19 in the coil forming member 10 showing an embodiment.

[0045] As Figure 1 、 Figure 2 and Figure 8 shown, the outer shape of each of the plurality of linear guides 19 is, for example, plate-like. Both surfaces in the thickness direction of each linear guide 19 are, for example, flat surfaces.

[0046] The plurality of linear guides 19 are arranged and stacked, for example, in a manner such that they are sequentially arranged outward from three of the four linear portions between adjacent corner portions of the base guide 13 where the displacement portions 13b are not provided. The innermost linear guide 19 at each linear portion and each linear portion of the base guide 13 sandwich the first turn of the electric wire 11 from both sides in the thickness direction. Adjacent linear guides 19 in the arrangement direction sandwich the (n + 1)-th turn of the electric wire 11 from both sides in the thickness direction (n is an arbitrary natural number). Each linear guide 19 causes the (n + 1)-th turn of the electric wire 11 to linearly advance along the outer peripheral surface 13A of each linear portion of the base guide 13, thereby forming a linear portion of the electric wire 11.

[0047] Each linear guide 19 includes, for example, a pair of claw portions 27a (second connecting members) and claw holding portions 27b (second connecting members) provided on both surfaces in the axial direction along a predetermined axis O. The claw holding portion 27b of the innermost linear guide 19 at each linear portion is mechanically engaged with each third base claw portion 13e (second connecting member) of each linear portion of the base guide 13 by a so-called cantilever type snap fit. Each third base claw portion 13e is a pair of third base claw portions 13e provided on both surfaces of each linear portion in the axial direction along a predetermined axis O. Among adjacent linear guides 19 in the arrangement direction, the claw holding portions 27b of the outer linear guide 19 are mechanically engaged with the claw portions 27a of the inner linear guide 19 by a so-called cantilever type snap fit. A through hole for inserting each third base claw portion 13e or each claw portion 27a is formed in each claw holding portion 27b, for example. Each claw holding portion 27b meshes the front end portion with each third base claw portion 13e or each claw portion 27a inserted into the through hole by elasticity, thereby fixing the innermost linear guide 19 at each linear portion and each linear portion of the base guide 13 to each other and fixing adjacent linear guides 19 in the arrangement direction to each other. The outermost linear guide 19 at each linear portion is supported, for example, by the inner peripheral surface 21A of the guide frame 21 and the convex portion 21a protruding inward from the inner peripheral surface 21A from at least one side of the outer side and the axial direction.

[0048] As Figure 1 、Figure 2 and Figure 4 As shown in Figure 4 , the guiding frame 21 has, for example, a winding end fixing portion 21b at a specified position on the inner circumferential portion for fixing the winding end portion 11b of the electric wire 11. The specified position on the inner circumferential portion is, for example, a straight portion such as a straight portion other than a bent corner portion, and is a position deviated toward the front side in the winding direction of the electric wire 11 from the outermost displacement guiding member 15. The winding end portion 11b of the electric wire 11 is, for example, a portion where the electric wire 11 is folded back in the width direction and then bent in the thickness direction. In the winding end fixing portion 21b, for example, a groove is formed that penetrates the guiding frame 21 in the axial direction along the specified axis O and in which the winding end portion 11b of the electric wire 11 is assembled.

[0049] Hereinafter, the coil forming process of the coil forming member 10 based on the embodiment will be described.

[0050] Figure 9 FIG. Figure 9 schematically shows the coil forming process of the coil forming member 10 based on the embodiment.

[0051] As Figure 9 shown in Figure 9 , first, after fixing the electric wire 11 to the winding start fixing portion 13a of the base guiding member 13, it is wound around the outer circumferential surface 13A of the base guiding member 13 (step S1).

[0052] When the first turn of the electric wire 11 is wound around the outer circumferential surface 13A, it is clamped from both sides in the thickness direction by the outer circumferential surface 13A and the displacement guiding member 15, corner guiding member 17, and straight guiding member 19 added from the outer side (step S2).

[0053] For the (n + 1)-th turn of the electric wire 11 after the second turn, it is wound around the outer surfaces in the thickness direction of the displacement guiding member 15, corner guiding member 17, and straight guiding member 19 (n is an arbitrary natural number). When the (n + 1)-th turn of the electric wire 11 is wound around the respective guiding members 15, 17, 19 on the inner side, it is clamped from both sides in the thickness direction by the outer surfaces of the respective guiding members 15, 17, 19 on the inner side and the inner surfaces in the thickness direction of the respective guiding members 15, 17, 19 added from the outer side (step S3).

[0054] Then, when the winding of the electric wire 11 of the final turn is completed around the respective guiding members 15, 17, 19, the guiding frame 21 is assembled along the axial direction with respect to the outermost guiding members 15, 17, 19. The outer surfaces of the outermost guiding members 15, 17, 19 are supported by the inner circumferential surface 21A of the guiding frame 21. The winding end portion 11b of the electric wire 11 of the final turn is fixed to the winding end fixing portion 21b (step S4).

[0055] As described above, the coil forming member 10 according to the embodiment includes a first base claw portion 13c, a claw portion 23a, and a claw holding portion 23b that connect the displacement portion 13b of the base guide member 13 and the plurality of displacement guide members 15. Thereby, it is possible to suppress the skew and deformation at the portion where the coiling position of the wire 11 is displaced outward, and improve the ease of the coil forming process of maintaining the interval between the wires 11 at a specified interval.

[0056] It includes a second base claw portion 13d, a claw portion 25a, and a claw holding portion 25b that connect the base guide member 13 and the plurality of corner guide members 17. Thereby, it is possible to suppress the skew and deformation at the bent portion of the wire 11, and improve the ease of the coil forming process of maintaining the interval between the wires 11 at a specified interval.

[0057] It includes a third base claw portion 13e, a claw portion 27a, and a claw holding portion 27b that connect the base guide member 13 and the plurality of straight guide members 19. Thereby, it is possible to suppress the skew and deformation at the straight portion of the wire 11, and improve the ease of the coil forming process of maintaining the interval between the wires 11 at a specified interval.

[0058] It includes a guide frame 21 that supports the outermost displacement guide member 15, corner guide member 17, and straight guide member 19 from the outer side. Thereby, even if the shape of the wire 11 is an easily deformable flat shape or the like, for example, deformation during handling can be suppressed.

[0059] By including a winding start fixing portion 13a and a winding end fixing portion 21b, deformation when the wire 11 is arranged in a spiral shape can be suppressed.

[0060] By adding each of the guide members 15, 17, 19 that support the wire 11 from the outer side when the wire 11 is arranged in a spiral shape, the position of the wire 11 in the axial direction can be maintained constant, and the skew and deformation of the wire 11 can be suppressed.

[0061] (Modification example)

[0062] It should be noted that in the above embodiment, the coil C is in a spiral shape of a rounded rectangle, but it is not limited thereto. For example, it can also be in other shapes such as a circular spiral shape.

[0063] It should be noted that in the above embodiment, the displacement portion 13b of the base guide member 13 is provided in the straight portion between adjacent corners, but it is not limited thereto. For example, it can also be provided at a corner or the like.

[0064] The embodiments of the present invention are presented as example embodiments and are not intended to limit the scope of the invention. These embodiments can be implemented in various other ways, and various omissions, substitutions, and changes can be made without departing from the gist of the invention. These embodiments and their modifications are included in the scope and gist of the invention, and are also included in the invention described in the claims and its equivalent scope.

Claims

1. A coil forming component, wherein: The coil forming member comprises: a first guide member around which the electric wire is wound in a first turn when the electric wire is arranged in a spiral shape around a predetermined axis; a second guide member that supports the bent portion of the electric wire of the nth turn at least from the outside, wherein n is an arbitrary natural number; a third guide member that supports the outermost second guide member from an outer side; and A plurality of connecting members connect the first guide member and the innermost second guide member and connect adjacent second guide members to each other.

2. The coil forming member according to claim 1, wherein Using the plurality of connecting members as first connecting members, The coil forming member comprises: a fourth guide member that supports the straight portion of the electric wire of the n-th turn at least from the outside; and A plurality of second connecting members connect the first guide member and the innermost fourth guide member and connect adjacent fourth guide members to each other.

3. The coil forming member according to claim 1 or 2, wherein: The first guide member includes a first fixing portion that fixes a winding start position of the electric wire. The third guide member includes a second fixing portion that fixes a winding end portion of the electric wire.

4. The coil forming member according to claim 3, wherein The first guide member includes a displacement portion that displaces the winding position of the first turn of the electric wire outward. The coil forming member comprises: a fifth guide member that displaces the winding position of the (n+1)th turn of the electric wire toward the outside; as well as A plurality of third coupling members couple the displacement portion and the innermost fifth guide member and couple adjacent fifth guide members to each other.

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