Coil device

Abstract

To provide a coil device which inhibit occurrence of stress in a core in a case to inhibit cracking of the core.SOLUTION: A coil device 100 includes: a core 1 formed in a plate-like shape; a core case 2 which is open at one side in a plate thickness direction A1 of the core 1 and houses the core 1; a coil unit 4 which has a coil 3 and a coil case 8 for housing the coil 3 and is disposed overlapping with the core case 2 at one side in the plate thickness direction A1; and an elastic member 30 formed of an elastically deformable material and sandwiched between the core 1 and the core case 2.SELECTED DRAWING: Figure 1

Description

[Technical Field]

[0001] The present disclosure relates to a coil device that can be used in a power supply device that uses electromagnetic induction to supply power to an object in a non-contact manner, or a power receiving device that receives power from an object in a non-contact manner. [Background technology]

[0002] An IH (Induction Heating) type induction heating cooker, as disclosed in Patent Document 1, is known as a power supply device that supplies electricity to an object in a non-contact manner. This induction heating cooker has a top plate on which a cooking container is placed, a heating coil that heats the cooking container, and a coil base on which the heating coil is placed. The coil base further includes a plurality of ferrite holders for holding ferrite cores. In addition to the induction heating cooker described above, other power supply devices that supply electricity to an object in a non-contact manner include wireless charging devices for smartphones. Furthermore, there is also a power receiving device that receives electricity from an object in a non-contact manner as a counterpart to the power supplying device. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] Japanese Patent Publication No. 2020-119693 Summary of the Invention [Problem to be solved by the invention]

[0004] Incidentally, the coil devices such as the power supply device and the power receiving device described above include a core (ferrite core) inside a case. Therefore, in the coil devices described above, when an external force acts on the core through the case, if a large stress is generated in the core due to the external force, the core may crack.

[0005] The present invention has been made in consideration of the above-mentioned circumstances, and aims to provide a coil device that can suppress the generation of stress in the core inside the case and prevent the core from cracking. [Means for solving the problem]

[0006] In order to solve this problem, the present invention comprises a core formed in a plate shape, a core case that opens on one side of the core in the plate thickness direction and houses the core, a coil unit that has a coil and a coil case that houses the coil and is arranged overlapping the core case on one side of the plate thickness direction, and an elastic member made of an elastically deformable material and sandwiched between the core and the core case. [Effects of the Invention]

[0007] In the present invention, an elastic member made of an elastically deformable material is installed between the core case and the core housed in the core case. Therefore, even if the core case is deformed due to an external force acting on the coil device, the deformation of the core case can be absorbed by the elastic member interposed between the core case and the core. This prevents the deformation of the core case from being transmitted to the core. Therefore, it is possible to prevent stress from being generated in the core housed in the core case due to the external force acting on the coil device, which could cause the core to crack. [Brief explanation of the drawings]

[0008] [Figure 1] 1 is a longitudinal sectional view of a coil component according to an embodiment of the present invention; [Figure 2] FIG. 2 is an enlarged cross-sectional view of a main part of FIG. DETAILED DESCRIPTION OF THE INVENTION

[0009] A coil device 100 according to one embodiment of the present invention will be described below with reference to FIGS. 1, the coil device 100 includes a core 1, a core case 2 in which the core 1 is housed, a coil unit 4 having a coil 3 and a coil case 8 in which the coil 3 is housed, a first elastic member 30, and a second elastic member 31. The coil device 100 of this embodiment also includes a housing 5 in which the core case 2 and the coil unit 4 are housed. In the coil device 100, by passing current through the coil 3, an inductive magnetic field is generated around the coil 3 to supply power to the outside in a non-contact manner, or by being located within the inductive magnetic field, power can be supplied from the outside in a non-contact manner.

[0010] In the following description, the vertical direction in the drawing is referred to as the plate thickness direction A1, and the horizontal direction is referred to as the plate surface direction A2. Furthermore, these vertical and horizontal directions are the directions of the coil device 100 shown in the drawing, and it goes without saying that if the orientation of the coil device 100 changes, these vertical and horizontal directions will also change.

[0011] 1 and 2, the core case 2 has an opening 6 that opens to one side (upper side in FIGS. 1 and 2) in the thickness direction A1 of the core 1. A concave core accommodating section 7 is formed in the opening 6 of the core case 2 to accommodate the core 1. The core 1 is a magnetic body made of ferrite and is formed into a plate shape as a whole. The core 1 is accommodated in a core accommodating portion 7 formed in the core case 2 along the plate surface direction A2. In FIG. 1, a plurality of core accommodating portions 7 are formed in a core case 2, and a plurality of cores 1 are accommodated in the individual core accommodating portions 7, respectively.

[0012] The coil unit 4 is arranged on one side in the plate thickness direction A1 (upper side in FIGS. 1 and 2) of the core case 2. An opening 9 is formed in the other side in the plate thickness direction A1 (lower side in FIGS. 1 and 2) of the coil case 8, which constitutes the coil unit 4 together with the coil 3. A concave coil accommodating portion 10 in which the coil 3 is accommodated is formed within the opening 9 of the coil unit 4. When the core case 2 and the coil unit 4 are stacked in the plate thickness direction A1, the core accommodating portion 7 of the core case 2 opens toward the coil unit 4 in the plate thickness direction A1. The coil accommodating portion 10 of the coil case 8 opens toward the core case 2 in the plate thickness direction A1. Furthermore, the core accommodating portion 7 and the coil accommodating portion 10 face each other in the plate thickness direction A1.

[0013] An insulating plate 11 made of an electrically insulating material is interposed between the core case 2 and the coil unit 4. The insulating plate 11 is disposed on the core case 2 along the plate surface direction A2 to electrically insulate the core 1 in the core case 2 from the coil 3 in the coil unit 4.

[0014] The housing 5 of this embodiment shown in FIG. 1 is composed of an aluminum cover 20 that forms the bottom, and a resin case 21 that is placed on the aluminum cover 20 and covers both the core case 2 and the coil unit 4. In FIG. 1, the aluminum cover 20 is formed in a flat plate shape with its thickness direction aligned in a plate thickness direction A1. The core case 2 is placed on top of the aluminum cover 20. Meanwhile, the resin case 21 is formed in a bowl shape that opens to the other side in the plate thickness direction A1 (the lower side in FIGS. 1 and 2). The bottom surface of the resin case 21 facing the other side in the plate thickness direction A1 (the lower side in FIGS. 1 and 2) is formed flat along the plate surface direction A2. The coil case 8 is placed on top of the bottom surface of the resin case 21.

[0015] The materials of the components of the housing 5 can be selected as appropriate. The specific form of the housing 5 (such as the shape of the components of the housing 5) may be arbitrary. The housing 5 can also be omitted as appropriate, provided that the core case 2 and the coil unit 4 have a certain level of strength or more.

[0016] The first elastic member 30 (elastic member) and the second elastic member 31 are both made of an elastically deformable material such as rubber. The first elastic member 30 is sandwiched between the core 1 and the core case 2. In this embodiment, the first elastic member 30 is an elastic sheet sandwiched between the core 1 and the core case 2 in the plate thickness direction A1. Specifically, the sheet-like first elastic member 30 is sandwiched between the lower surface of the core 1 and the bottom surface of the core accommodating portion 7 of the core case 2 in the plate thickness direction A1. In addition, the first elastic member 30 is arranged so as to cover the entire lower surface of the core 1.

[0017] The second elastic member 31 is sandwiched between the core 1 and the coil case 8. In this embodiment, the second elastic member 31 is an elastic sheet sandwiched between the upper surface of the core 1 and the coil case 8 in the plate thickness direction A1. Specifically, the sheet-like second elastic member 31 is arranged so as to cover the entire upper surface of the core 1. As a result, a first elastic member 30 and a second elastic member 31 are installed on the lower and upper surfaces of the core 1 accommodated in the core accommodating section 7 of the core case 2, sandwiching the entire upper and lower plate surfaces of the core 1 from both sides in the plate thickness direction A1.

[0018] These first elastic member 30 and second elastic member 31 can absorb deformation even when the core case 2 or the coil case 8 is deformed by an external force from the plate thickness direction A1. This can prevent deformation of the core case 2 or the coil case 8 from being transmitted to the core 1 inside the core case 2. As a result, stress can be prevented from being generated in the core 1 inside the core case 2, and furthermore, cracking of the core 1 can be prevented.

[0019] By selecting a material with high thermal conductivity for the first elastic member 30 and the second elastic member 31, they can also function as heat dissipation sheets. In this case, the first elastic member 30 and the second elastic member 31 can also dissipate heat generated in the core 1 in the core case 2 or heat generated in the coil 3 in the coil unit 4 to the outside through the core case 2 and the stacked coil unit 4.

[0020] As described above in detail, in the coil device 100 of this embodiment, the first elastic member 30 is sandwiched between the core 1 and the core case 2. Therefore, even if the core case 2 is deformed due to an external force acting on the coil device 100, the deformation of the core case 2 can be absorbed by the first elastic member 30 interposed between the core 1 and the core case 2. This makes it possible to prevent the deformation of the core case 2 from being transmitted to the core 1. In other words, it is possible to prevent stress from being generated in the core 1 due to the deformation of the core case 2. Therefore, it is possible to prevent the core 1 from cracking due to an external force acting on the coil device 100.

[0021] In particular, in this embodiment, the first elastic member 30 is an elastic sheet sandwiched between the core 1 and the core case 2 in the plate thickness direction A1. This makes it possible to more effectively prevent the core 1 from cracking when an external force acts on the coil device 100 in the plate thickness direction A1.

[0022] Furthermore, because the first elastic member 30 is sandwiched between the core 1 and the core case 2, there is no need to adhesively fix the core 1 to the core case 2. Since the core 1 is not adhesively fixed to the core case 2, the core 1 can be easily removed from the core case 2 during maintenance of the coil device 100, and the core 1 can also be easily replaced.

[0023] Furthermore, in the coil device 100, the second elastic member 31 is sandwiched between the core 1 and the coil case 8 in the plate thickness direction A1, so that the core 1 is sandwiched between the core case 2 and the coil case 8 via the first elastic member 30 and the second elastic member 31. This prevents the core 1 from moving freely within the core case 2 and cracking due to vibrations during earthquakes, transportation, or the like.

[0024] Furthermore, in the coil device 100, the second elastic member 31 made of an elastic sheet is further interposed between the core 1 and the coil case 8. Therefore, even if an external force acts on the coil device 100 in the plate thickness direction A1, causing the coil case 8 to deform, the deformation of the coil case 8 can be absorbed by the second elastic member 31. Therefore, in particular, the second elastic member 31 can effectively prevent the deformation of the coil case 8 from being transmitted to the core 1. Therefore, it is possible to prevent the core 1 from cracking due to stress generated in the core 1 based on the deformation of the coil case 8.

[0025] As described above, the first elastic member 30 and the second elastic member 31 made of an elastically deformable material are provided on the bottom and top surfaces of the core 1 housed in the core case 2, so even if the core case 2 or the coil case 8 is deformed by an external force, the deformation can be absorbed by these elastic members 30, 31. As a result, in the coil device 100, even if the core case 2 or the coil case 8 is deformed by an external force from the plate thickness direction A1, the deformation can be prevented from generating stress in the core 1 inside the core case 2 via the core case 2 or the coil case 8, and cracking of the core 1 can be prevented.

[0026] Furthermore, in the coil device 100, the core 1 is sandwiched between the core case 2 and the coil unit 4 via the elastic members 30 and 31. This allows the core 1 to be accommodated in the core accommodating portion 7 of the core case 2 without being adhesively fixed to the core case 2. Therefore, the core 1 can be easily removed from the core case 2 and replaced during maintenance or the like.

[0027] Furthermore, in the coil device 100, heat generated in the core 1 when a current flows through the coil 3 (for example, when current is applied to the power transmission coil 3) or heat transferred from the coil 3 to the core 1 can be efficiently released via the first elastic member 30 and the second elastic member 31, which serve as heat dissipation sheets with high thermal conductivity. That is, in the coil device 100, heat generated in the core 1 in the core case 2 or heat generated in the coil 3 in the coil unit 4 can be efficiently released to the outside via the first elastic member 30 and the second elastic member 31, which serve as heat dissipation sheets, thereby improving the heat dissipation performance of the device.

[0028] In the above embodiment, for example, the second elastic member 31 arranged on the upper surface of the core 1 may have a sufficient electrical insulating function. In this case, the coil device 100 does not need to include the insulating plate 11 arranged between the core case 2 and the coil unit 4.

[0029] Furthermore, the first elastic member 30 and the second elastic member 31 located on the lower and upper surfaces of the core 1 do not have to be arranged to cover the entire upper and lower plate surfaces of the core 1, but may be arranged, for example, to cover only part of the upper and lower plate surfaces of the core 1.

[0030] Furthermore, the first elastic member 30 is not limited to being sandwiched between the lower surface of the core 1 and the bottom surface of the core accommodating portion 7 of the core case 2, but may be sandwiched, for example, between the side surface of the core 1 and the inner surface of the core accommodating portion 7. In this case, the first elastic member 30 may be arranged so as to cover the entire side surface of the core 1, or may be arranged so as to cover only a portion of the side surface of the core 1, for example.

[0031] Although the embodiments have been described above, various modifications can be made to the configurations and details thereof that would be understood by those skilled in the art. Furthermore, the embodiments can be combined with other examples as appropriate. [Explanation of symbols]

[0032] 1 core 2 Core Case 3 coils 4 Coil Unit 5. Cabinet 6 Opening 7 Core housing 8 Coil case 9 Openings 10 Coil storage section 11 Insulating plate 20 Aluminum cover 21 Resin case 30 First elastic member 31 Second elastic member 100 Coil device A1 Thickness direction A2 plate direction

Claims

1. a core formed in a plate shape; a core case that opens to one side of the core in a thickness direction and accommodates the core; a coil unit including a coil and a coil case in which the coil is housed, the coil unit being disposed on one side of the core case in the plate thickness direction; a coil device comprising: an elastic member made of an elastically deformable material and sandwiched between the core and the core case;

2. The coil device according to claim 1 , wherein the elastic member is an elastic sheet sandwiched between the core and the core case in the thickness direction.

3. The coil device according to claim 1 , further comprising a second elastic member made of an elastic sheet made of an elastically deformable material and sandwiched between the core and the coil case in the thickness direction.

4. 4. The coil device according to claim 2, wherein the elastic sheet is a heat dissipation sheet.

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