Coil molding member

Abstract

To provide a coil molding member capable of improving easiness of a coil molding.SOLUTION: A coil molding member 10 comprises a base guide 13, a corner guide 17, and a guide frame 21. In the base guide 13, an electric wire 11 is wound at a first turn in the case where the electric wire 11 is arranged in a spiral shape to a circumference of a center axis O. The corner guide 17 supports a curvature part of the electric wire 11 at an n-th turn by an optional natural number n from an external side. The guide frame 21 supports the corner guide 17 at the outermost side from the external side. A second base claw part 13d of the base guide 13, a claw part 25a of the corner guide 17, and a claw holding part 25b connect the base guide 13 with the corner guide 17 at the inner most side, and connect the adjacent corner guides 17 by a so-called cantilever type snap fitting.SELECTED DRAWING: Figure 2

Description

Technical Field

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

Background Art

[0002] In recent years, in order to enable more people to access affordable, reliable, sustainable, and advanced energy, research and development have been carried out on charging and discharging of vehicles equipped with secondary batteries that contribute to energy efficiency. Conventionally, in a non-contact power transmission system that supplies power to a vehicle from outside the vehicle by non-contact power transmission, in a power transmission device and a power reception device, a planar coil formed in a spiral shape while providing a gap between windings is known (see, for example, Patent Document 1). Conventionally, when providing a gap between windings, a method of fitting a winding into a guide groove formed in a support substrate or a method of providing a spacer between windings is known (see, for example, Patent Document 2).

Prior Art Documents

Patent Documents

[0003]

Patent Document 1

Patent Document 2

Summary of the Invention

Problems to be Solved by the Invention

[0004] By the way, in the technology related to charging and discharging of vehicles equipped with secondary batteries, it is desired to improve the ease of a coil forming process that maintains a predetermined interval between windings while suppressing distortion and strain of windings provided in a power transmission device and a power reception device. For example, when providing a plurality of spacers between spiral windings such as the planar coil of the above conventional technology, a problem occurs in that it becomes difficult to improve the ease of coil forming due to displacement of the plurality of spacers.

[0005] The present invention aims to provide a coil forming member that can improve the ease of coil forming, and by extension, contributes to energy efficiency.

Means for Solving the Problems

[0006] In order to solve the above problems and achieve the related object, the present invention adopts the following aspects. (1): A coil forming member according to an aspect of the present invention (for example, the coil forming member 10 in the embodiment) includes a first guide member (for example, the base guide 13 in the embodiment) around which an electric wire (for example, the electric wire 11 in the embodiment) is wound in the first round when the electric wire is arranged in a spiral shape around a predetermined axis (for example, the central axis O in the embodiment), a second guide member (for example, the corner guide 17 in the embodiment) that supports at least the curved portion of the electric wire in the nth round by any natural number n from at least the outer side, a third guide member (for example, the guide frame 21 in the embodiment) that supports the outermost second guide member from the outer side, and a plurality of connecting members (for example, the second base claw portion 13d, the claw portion 25a, and the claw holding portion 25b in the embodiment) that connect the first guide member and the innermost second guide member and connect adjacent second guide members to each other.

[0007] (2): The coil forming member described in (1) above may include a plurality of the connecting members as first connecting members (for example, the second base claw portion 13d, the claw portion 25a, and the claw holding portion 25b in the embodiment), a fourth guide member (for example, the straight guide 19 in the embodiment) that supports at least the straight portion of the electric wire in the nth round from at least the outer side, and a plurality of second connecting members (for example, the third base claw portion 13e, the claw portion 27a, and the claw holding portion 27b in the embodiment) that connect the first guide member and the innermost fourth guide member and connect adjacent fourth guide members to each other.

[0008] (3): In the coil forming member described in the above (1) or (2), the first guide member may include a first fixing portion (for example, the start winding fixing portion 13a in the embodiment) for fixing the start winding portion of the electric wire (for example, the start winding portion 11a in the embodiment), and the third guide member may include a second fixing portion (for example, the end winding fixing portion 21b in the embodiment) for fixing the end winding portion of the electric wire (for example, the end winding portion 11b in the embodiment).

[0009] (4): The coil forming member described in the above (3) may include a displacement portion (for example, the displacement portion 13b in the embodiment) in which the first guide member displaces the circumferential position of the electric wire in the first round to the outer side, a fifth guide member (for example, the displacement guide 15 in the embodiment) that displaces the circumferential position of the electric wire in the (n + 1)th round to the outer side, and a plurality of third connecting members (for example, the first base claw portion 13c, the claw portion 23a, and the claw holding portion 23b in the embodiment) that connect the displacement portion and the innermost fifth guide member and connect the adjacent fifth guide members.

Advantages of the Invention

[0010] According to the above (1), by providing a plurality of connecting members that connect the first guide member and the plurality of second guide members, the ease of the coil forming process of maintaining a predetermined interval between electric wires while suppressing distortion and strain at the bent portion of the electric wire can be improved. By adding a second guide member that supports the bent portion from the outer side when the electric wires are arranged in a spiral shape, it is possible to suppress distortion and strain of the electric wires while maintaining the position of the electric wires in the axial direction constant. By providing a third member that supports the outermost second guide member from the outer side, it is possible to suppress distortion during conveyance, etc., even when the shape of the electric wire is a flat shape or the like that is easily distorted.

[0011] In the case of the above (2), by providing a plurality of second connecting members that connect the first guide member and the plurality of fourth guide members, it is possible to improve the ease of the coil forming process of maintaining a predetermined interval between the electric wires while suppressing the distortion and strain in the straight portion of the electric wire.

[0012] In the case of the above (3), by providing the first fixing portion and the second fixing portion, it is possible to suppress the strain when the electric wire is arranged in a spiral shape.

[0013] In the case of the above (4), by providing a plurality of third connecting members that connect the displacement portion of the first guide member and the plurality of fifth guide members, it is possible to improve the ease of the coil forming process of maintaining a predetermined interval between the electric wires while suppressing the distortion and strain at the portion where the circumferential position of the electric wire is displaced outward.

Brief Description of the Drawings

[0014]

Figure 1

Figure 2

Figure 3

Figure 4

Figure 5

Figure 6

Figure 7

Figure 8

Figure 9

Embodiments for Carrying Out the Invention

[0015] Hereinafter, a coil forming member according to an embodiment of the present invention will be described with reference to the accompanying drawings. FIG. 1 is a perspective view showing the configuration of a coil forming member 10 according to an embodiment. FIG. 2 is a plan view of the coil forming member 10 according to the embodiment as viewed from the axial direction along the central axis O. The coil forming member 10 according to the embodiment is used, for example, for forming a coil C provided 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 an electric car, a hybrid vehicle, and a fuel cell vehicle. As shown in FIGS. 1 and 2, the coil C according to the embodiment is formed, for example, by arranging a wire 11 such as a flat copper wire around a predetermined axis O in a rounded rectangular spiral shape by the coil forming member 10.

[0016] The coil forming member 10 according to the embodiment includes, for example, a base guide 13, a plurality of displacement guides 15, a plurality of corner guides 17, a plurality of straight guides 19, and a guide frame 21. The outer shape of the base guide 13 is, for example, a rounded rectangular frame shape. The base guide 13 includes an outer peripheral surface 13A around which the wire 11 of the first turn in the spiral coil C is wound. FIG. 3 is a perspective view showing a winding start fixing portion 13a of the base guide 13 in the coil forming member 10 according to the embodiment. As shown in FIG. 3, the base guide 13 includes, for example, a start fixing portion 13a that fixes the start winding portion 11a of the electric wire 11 at a predetermined position on the outer peripheral portion. The predetermined position on the outer peripheral portion is, for example, a straight portion other than the curved corner portion, etc. The start winding portion 11a of the electric wire 11 is, for example, a portion where the electric wire 11 is folded back in the width direction after being bent in the thickness direction. In the start fixing portion 13a, for example, a groove is formed that penetrates the base guide 13 in the axial direction along a predetermined axis O and to which the start winding portion 11a of the electric wire 11 is attached.

[0017] As shown in FIGS. 1 and 2, the base guide 13 includes, for example, a displacement portion 13b provided at a position displaced in the circumferential direction of the electric wire 11 along the outer peripheral portion from the start fixing portion 13a. The displacement portion 13b increases the thickness of the base guide 13, for example, by bulging outward in a direction orthogonal to the outer peripheral portion. 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 circumferential direction. The displacement portion 13b displaces the circumferential position around the start of the first turn of the electric wire 11 outward, so that the circumferential position around the start of the second turn of the electric wire 11 is shifted to the outside (the outside which is the winding increase side of the coil C) compared to the circumferential position around the start of the first turn of the electric wire 11.

[0018] FIG. 4 is a perspective view showing the configuration of the end fixing portion 21b of the guide frame 21 and the displacement guide 15 in the coil forming member 10 of the embodiment. As shown in FIGS. 1, 2, and 4, the outer shape of each of the plurality of displacement guides 15 is, for example, a plate shape curved in an S shape. Both surfaces in the thickness direction of each displacement guide 15 are, for example, curved surfaces with shapes corresponding to contact the outer surface of the displacement portion 13b and curved surfaces having the same shape as the outer surface of the displacement portion 13b. The plurality of displacement guides 15 are arranged, for example, so as to be sequentially arranged and stacked 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 wire 11 from both sides in the thickness direction. Adjacent displacement guides 15 in the arrangement direction sandwich the wire 11 of the (n + 1)-th turn for any natural number n from both sides in the thickness direction. Each displacement guide 15, for example, displaces the circumferential position at the start of winding of the wire 11 of the (n + 1)-th turn outward, thereby shifting the circumferential position at the start of winding of the wire 11 of the (n + 2)-th turn to the outside (the outside which is the side of increasing the winding of the coil C) of the circumferential position at the start of winding of the wire 11 of the (n + 1)-th turn.

[0019] Each displacement guide 15 includes, for example, a pair of claw portions 23a and claw holding portions 23b provided on both surfaces in the axial direction along a predetermined axis O. Each claw holding portion 23b of the innermost displacement guide 15 is mechanically joined to each first base claw portion 13c of the displacement portion 13b of the base guide 13 by a so-called cantilever type snap fit. Each first base claw portion 13c is each of a pair of first base claw portions 13c provided on both surfaces of the displacement portion 13b in the axial direction along the predetermined axis O. Between adjacent displacement guides 15 in the arrangement direction, each claw holding portion 23b of the outer displacement guide 15 is mechanically joined to each claw portion 23a of the inner displacement guide 15 by a so-called cantilever type snap fit. 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, for example. Each claw holding portion 23b fixes the innermost displacement guide 15 and the displacement portion 13b of the base guide 13 to each other and fixes adjacent displacement guides 15 to each other in the arrangement direction by elastically engaging the tip portion with each first base claw portion 13c or each claw portion 23a inserted into the through hole. The outermost displacement guide 15 is supported, for example, by the inner peripheral surface 21A of the guide frame 21 and a convex portion 21a protruding inward from the inner peripheral surface 21A from at least one side of the outer side and the axial direction.

[0020] FIG. 5 is a perspective view showing the corner guide 17 in the coil forming member 10 of the embodiment. FIG. 6 is a perspective view showing a part of each of the base guide 13, the guide frame 21, and the corner guide 17 in the coil forming member 10 of the embodiment with a break. FIG. 7 is a plan view of the corner guide 17 in the coil forming member 10 of the embodiment as viewed from the axial direction along the central axis O. As shown in FIGS. 1, 2, 5, 6, and 7, the outer shape of each of the plurality of corner guides 17 is, for example, a plate shape curved in a U shape. Both surfaces in the thickness direction of each corner guide 17 are provided with a curved surface having a shape corresponding to contact the outer peripheral surface 13A of each of the four corners of the base guide 13, and a curved surface having the same shape as the outer peripheral surface 13A of each corner. The plurality of corner guides 17 are arranged, for example, so as to be 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. 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 for any natural number n. Each corner guide 17 forms a curved portion of the electric wire 11, for example, by curving the (n + 1)th turn of the electric wire 11 along the outer peripheral surface 13A of each corner of the base guide 13.

[0021] Each corner guide 17 includes, for example, a pair of claw portions 25a and claw holding portions 25b 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 joined to each second base claw portion 13d at each corner of the base guide 13 by a so-called cantilever type snap fit. Each second base claw portion 13d is each of a pair of second base claw portions 13d provided on both surfaces at each corner in the axial direction along the predetermined axis O. Between adjacent corner guides 17 in the alignment direction, each claw holding portion 25b of the outer corner guide 17 is mechanically joined to each claw portion 25a of the inner corner guide 17 by a so-called cantilever type snap fit. Each claw holding portion 25b is formed with a through hole into which, for example, each second base claw portion 13d or each claw portion 25a is inserted. Each claw holding portion 25b fixes the innermost corner guide 17 at each corner and each corner of the base guide 13 to each other, and also fixes adjacent corner guides 17 in the alignment direction to each other, by elastically engaging the tip portion with each second base claw portion 13d or each claw portion 25a inserted into the through hole. The outermost corner guide 17 at each corner is supported, for example, by the inner peripheral surface 21A of the guide frame 21 and a convex portion 21a protruding inward from the inner peripheral surface 21A, from at least one side of the outer side and the axial direction.

[0022] As shown in FIG. 7, each corner guide 17 includes, for example, a curved plate-like portion 17a and two straight plate-like portions 17b provided at both ends of the curved plate-like portion 17a. For example, the curved plate-like portion 17a curves the electric wire 11 along an arc of a predetermined central angle such as 90°. For example, the two straight plate-like portions 17b cause the electric wire 11 to travel straight along a direction intersecting at a predetermined angle such as 90° with each other.

[0023] FIG. 8 is a perspective view showing the straight guide 19 in the coil forming member 10 of the embodiment. As shown in FIGS. 1, 2, and 8, the outer shape of each of the plurality of straight guides 19 is, for example, flat plate-shaped. Both surfaces of each straight guide 19 in the thickness direction are, for example, flat surfaces. The plurality of straight guides 19 are arranged so as to be sequentially arranged and stacked outward from each of the three straight portions among the four straight portions between adjacent corners of the base guide 13 where the displacement portion 13b is not provided. The innermost straight guide 19 at each straight portion and each straight portion of the base guide 13 sandwich the first turn of the electric wire 11 from both sides in the thickness direction. Adjacent straight guides 19 in the arrangement direction sandwich the (n + 1)-th turn of the electric wire 11 from both sides in the thickness direction for any natural number n. Each straight guide 19 forms a straight portion of the electric wire 11, for example, by causing the (n + 1)-th turn of the electric wire 11 to travel straight along the outer peripheral surface 13A of each straight portion of the base guide 13.

[0024] Each straight guide 19 includes, for example, a pair of claw portions 27a and claw holding portions 27b provided on both surfaces in the axial direction along a predetermined axis O. The claw holding portion 27b of the innermost straight guide 19 in each straight portion is mechanically joined to each third base claw portion 13e of each straight portion of the base guide 13 by a so-called cantilever type snap fit. Each third base claw portion 13e is each of a pair of third base claw portions 13e provided on both surfaces of each straight portion in the axial direction along the predetermined axis O. Between adjacent straight guides 19 in the arrangement direction, each claw holding portion 27b of the outer straight guide 19 is mechanically joined to each claw portion 27a of the inner straight guide 19 by a so-called cantilever type snap fit. A through hole into which each third base claw portion 13e or each claw portion 27a is inserted is formed in each claw holding portion 27b, for example. Each claw holding portion 27b elastically meshes the tip portion with each third base claw portion 13e or each claw portion 27a inserted into the through hole, thereby fixing the innermost straight guide 19 in each straight portion and each straight portion of the base guide 13 to each other, and fixing adjacent straight guides 19 in the arrangement direction to each other. The outermost straight guide 19 in each straight portion is supported, for example, by the inner peripheral surface 21A of the guide frame 21 and a convex portion 21a protruding inward from the inner peripheral surface 21A from at least one of the outer side and the axial direction side.

[0025] As shown in FIGS. 1, 2, and 4, the guide frame 21 includes, for example, a winding end fixing portion 21b for fixing the winding end portion 11b of the electric wire 11 at a predetermined position in the inner peripheral portion. The predetermined position in the inner peripheral portion is, for example, a straight portion such as other than a curved corner portion, and a position shifted to the front side in the circumferential direction of the electric wire 11 from the outermost displacement guide 15, etc. 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. A groove is formed in the winding end fixing portion 21b, for example, which penetrates the guide frame 21 in the axial direction along the predetermined axis O and to which the winding end portion 11b of the electric wire 11 is attached.

[0026] The coil forming process by the coil forming member 10 of the embodiment will be described below. FIG. 9 is a diagram schematically showing the coil forming process by the coil forming member 10 of the embodiment. As shown in FIG. 9, first, after the electric wire 11 is fixed to the start winding fixing portion 13a of the base guide 13, it is wound around the outer peripheral surface 13A of the base guide 13 (step S1). When the first turn of the electric wire 11 is wound around the outer peripheral surface 13A, it is sandwiched from both sides in the thickness direction by the displacement guide 15, the corner guide 17, and the straight guide 19 added from the outer side, and the outer peripheral surface 13A (step S2). The (n + 1)-th turn of the electric wire 11 for any natural number n after the second turn is wound around the outer surfaces in the thickness direction of the displacement guide 15, the corner guide 17, and the straight guide 19. When the (n + 1)-th turn of the electric wire 11 is wound around the inner guides 15, 17, 19, it is sandwiched from both sides in the thickness direction by the outer surfaces of the inner guides 15, 17, 19 and the inner surfaces in the thickness direction of the guides 15, 17, 19 added from the outer side (step S3). Then, when the winding of the electric wire 11 of the final turn around each of the guides 15, 17, 19 is completed, the guide frame 21 is attached along the axial direction to the outermost guides 15, 17, 19. The outer surfaces of the outermost guides 15, 17, 19 are supported by the inner peripheral surface 21A of the guide frame 21. The end winding portion 11b of the electric wire 11 of the final turn is fixed to the end winding fixing portion 21b (step S4).

[0027] As described above, according to the coil forming member 10 of the embodiment, by providing the first base claw portion 13c, the claw portion 23a, and the claw holding portion 23b that connect the displacement portion 13b of the base guide 13 and the plurality of displacement guides 15, it is possible to improve the ease of the coil forming process of maintaining the interval between the electric wires 11 at a predetermined value while suppressing the distortion and strain at the portion where the circumferential position of the electric wire 11 is displaced outward. By providing a second base claw portion 13d, a claw portion 25a, and a claw holding portion 25b that connect the base guide 13 and the plurality of corner guides 17, it is possible to improve the ease of the coil forming process of maintaining a predetermined interval between the electric wires 11 while suppressing distortion and strain in the bent portion of the electric wire 11. By providing a third base claw portion 13e, a claw portion 27a, and a claw holding portion 27b that connect the base guide 13 and the plurality of straight guides 19, it is possible to improve the ease of the coil forming process of maintaining a predetermined interval between the electric wires 11 while suppressing distortion and strain in the straight portion of the electric wire 11.

[0028] By providing a guide frame 21 that supports the outermost displacement guide 15, the corner guide 17, and the straight guide 19 from the outer side, it is possible to suppress distortion during conveyance or the like even when the shape of the electric wire 11 is a flat shape or the like that is easily distorted. By providing a winding start fixing portion 13a and a winding end fixing portion 21b, it is possible to suppress strain when the electric wire 11 is arranged in a spiral shape.

[0029] By adding the guides 15, 17, 19 that support the electric wire 11 from the outer side when the electric wire 11 is arranged in a spiral shape, it is possible to suppress distortion and strain of the electric wire 11 while maintaining the position of the electric wire 11 in the axial direction constant.

[0030] (Modification example) In the above-described embodiment, the coil C is assumed to be a rounded rectangular spiral shape, but it is not limited thereto, and other shapes such as a circular spiral shape may be used. In the above-described embodiment, the displacement portion 13b of the base guide 13 is provided in the straight portion between adjacent corners, but it is not limited thereto, and it may be provided at a corner or the like, for example.

[0031] Embodiments of the present invention are presented as examples and are not intended to limit the scope of the invention. These embodiments can be implemented in various other forms, and various omissions, replacements, 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, as well as in the invention described in the claims and the equivalent scope thereof.

Explanation of Reference Numerals

[0032] 10... Coil forming member, 11... Electric wire, 11a... Start winding site, 11b... End winding site, 13... Base guide (first guide member), 13a... Start winding fixing part (first fixing part), 13b... Displacement part, 13c... First base claw part (third connecting member), 13d... Second base claw part (connecting member, first connecting member), 13e... Third base claw part (second connecting member), 15... Displacement guide (fifth guide member), 17... Corner guide (second guide member), 19... Straight guide (fourth guide member), 21... Guide frame (third guide member), 21b... End winding fixing part (second fixing part), 23a... Claw part (third connecting member), 23b... Claw holding part (third connecting member), 25a... Claw part (connecting member, first connecting member), 25b... Claw holding part (connecting member, first connecting member), 27a... Claw part (second connecting member), 27b... Claw holding part (second connecting member), C... Coil, O... Central axis (predetermined axis).

Claims

1. a first guide member around which the wire is wound in the first round when the wire is arranged in a spiral around a predetermined axis; a second guide member that supports at least the curved portion of the wire in the n-th round by any natural number n from the outer side; a third guide member that supports the outermost second guide member from the outer side; a plurality of connecting members that connect the first guide member and the innermost second guide member and connect adjacent second guide members to each other comprising a coil forming member.

2. Regarding a plurality of the connecting members as first connecting members, a fourth guide member that supports at least the straight portion of the wire in the n-th round from the outer side; a plurality of second connecting members that connect the first guide member and the innermost fourth guide member and connect adjacent fourth guide members to each other comprising the coil forming member according to Claim 1.

3. The first guide member includes a first fixing portion that fixes the starting portion of the winding of the wire, The third guide member includes a second fixing portion that fixes the ending portion of the winding of the wire The coil forming member according to Claim 1 or Claim 2.

4. The first guide member includes a displacement portion that displaces the circumferential position of the wire in the first round to the outer side, a fifth guide member that displaces the circumferential position of the wire in the (n + 1)-th round to the outer side, a plurality of third connecting members that connect the displacement portion and the innermost fifth guide member and connect adjacent fifth guide members to each other comprising the coil forming member according to Claim 3.

Images