Coil unit and method for manufacturing the coil unit

Abstract

To realize a coil unit in which each member constituting the coil unit can be appropriately integrated and the cost can be easily reduced.SOLUTION: Between a curved portion 210 of a first coil body 21 and a curved portion 220 of a second coil body 22 in the first direction X, a fixing member 4 is arranged. The fixing member 4 includes a fixed portion fixed to a support plate 1, and an extension portion 42 arranged to extend from the fixed portion to the side on which the first coil body 21 and the second coil body 22 are arranged with respect to the support surface. The first coil body 21, the second coil body 22, and the extension portion 42 are embedded in a mold resin 3, and the mold resin 3 and the support plate 1 are integrally joined.SELECTED DRAWING: Figure 2

Description

[Technical field]

[0001] The present invention relates to a coil unit including a support plate, a coil arranged along a support surface of the support plate, and a molding resin, and to a method for manufacturing the coil unit. [Background technology]

[0002] For example, Japanese Patent No. 5958423 (Patent Document 1) discloses a coil unit used for contactless power supply to a forklift equipped with a battery. In the following description of the background art, the reference numerals in parentheses refer to those in Patent Document 1.

[0003] In the technology disclosed in Patent Document 1, a space is formed between the floor plate (5) and the side plate (8), and the coils (9, 10) and ferrite (7) are placed in this space and resin (17) is injected into the space. In this way, the floor plate (5), the side plate (8), the coils (9, 10), and the ferrite (7) are integrated with the resin (17) to form a coil unit. [Prior art documents] [Patent documents]

[0004] [Patent Document 1] Patent No. 5958423 Summary of the Invention [Problem to be solved by the invention]

[0005] However, in the technology disclosed in Patent Document 1, space forming members such as a floor plate (5) and a side plate (8) are used to form a space for arranging the coils (9, 10), the ferrite (7), and the resin (17), and these floor plate (5) and side plate (8) become part of the completed coil unit. Therefore, there is a problem that the number of parts constituting the coil unit increases, which causes high costs.

[0006] In view of the above circumstances, it is desirable to realize a coil unit in which the components constituting the coil unit can be appropriately integrated and which can be easily manufactured at low cost. [Means for solving the problem]

[0007] A coil unit including a support plate, a coil disposed along a support surface of the support plate, and a mold resin, The coil includes a first coil body and a second coil body that are each formed in an annular shape when viewed in a normal direction along the normal direction of the support surface, and that are arranged adjacent to each other in a first direction that is a specific direction along the support surface, A direction perpendicular to the first direction when viewed in the normal direction is defined as a second direction, each of the first coil body and the second coil body includes a curved portion formed in a portion facing each other in the first direction so as to extend toward an outer side in the second direction and toward a side that separates from each other in the first direction; a fixing member is disposed between the curved portion of the first coil body and the curved portion of the second coil body in the first direction; the fixing member has a fixing portion fixed to the support plate and an extending portion arranged to extend from the fixing portion to a side where the first coil body and the second coil body are arranged with respect to the support surface, The first coil body, the second coil body, and the extension portion are embedded in the molding resin, and the molding resin and the support plate are integrally joined together.

[0008] When a space forming member for forming a space in which a coil or molded resin is arranged is used as in the past, each member including the space forming member is joined to the molded resin, so that each member can be properly integrated. However, when forming a coil unit without using such a space forming member, it is necessary to properly integrate the molded resin and the member in contact with the molded resin. According to this configuration, since the fixing portion of the fixing member is fixed to the support plate and the extension portion of the fixing member is embedded in the molded resin, the molded resin and the support plate can be properly integrated, and thus the first coil body and the second coil body embedded in the molded resin can be properly integrated with the support plate. Furthermore, according to this configuration, since the fixing member is disposed in the dead space between the curved portion of the first coil body and the curved portion of the second coil body in the first direction, the molded resin and the support plate can be properly integrated while suppressing the expansion of the dimensions of the coil unit. As described above, according to this configuration, each member constituting the coil unit can be properly integrated, and a coil unit that is easy to reduce costs can be realized.

[0009] A method for manufacturing a coil unit including a support plate, a coil, and a molding resin, comprising the steps of: a coil arrangement step of arranging the coil including a first coil body and a second coil body along a support surface of the support plate, a fixing member arrangement step of arranging a fixing member, and a resin supply step of supplying a resin, which is performed after the coil arrangement step and the fixing member arrangement step, In the coil arrangement step, the first coil body and the second coil body are each formed into an annular shape when viewed in a normal direction along the normal direction of the support surface, and the first coil body and the second coil body are arranged so as to be adjacent to each other in a first direction, which is a specific direction along the support surface; A direction perpendicular to the first direction when viewed in the normal direction is defined as a second direction, a curved portion is a portion of each of the first coil body and the second coil body that faces each other in the first direction and is formed so as to move toward a side that moves away from each other in the first direction as it moves toward the outside in the second direction, In the fixing member arrangement step, the fixing member is arranged between the curved portion of the first coil body and the curved portion of the second coil body in the first direction, a fixing portion of the fixing member is fixed to the support plate, and an extension portion extending from the fixing portion is arranged so as to extend on a side where the first coil body and the second coil body are arranged with respect to the support surface; In the resin supplying step, the resin is supplied to a region adjacent to the support surface of the support plate so that the first coil body, the second coil body, and the extension portion are embedded in the resin.

[0010] According to this configuration, the fixing member is fixed to the support plate by the fixing portion in the fixing member arrangement step, and then the extension portion of the fixing member is embedded in the resin in the resin supply step, so that the molded resin formed by the hardening of the resin can be appropriately integrated with the support plate. This allows the first coil body and the second coil body embedded in the molded resin to be appropriately integrated with the support plate. Furthermore, according to this configuration, the fixing member is arranged in the dead space between the curved portion of the first coil body and the curved portion of the second coil body in the first direction, so that the molded resin can be appropriately integrated with the support plate while suppressing an increase in the dimensions of the coil unit. As described above, according to this configuration, it is possible to realize a coil unit that can be appropriately integrated with each member constituting the coil unit and can easily reduce costs.

[0011] Further features and advantages of the techniques disclosed herein will become more apparent from the following description of exemplary and non-limiting embodiments, which proceeds with reference to the drawings. [Brief description of the drawings]

[0012] [Figure 1] A diagram showing an example of how to use a coil unit [Diagram 2] Normal view of coil unit [Diagram 3] Cross-sectional view of FIG. 2 taken along the line III-III [Figure 4] Flowchart showing the manufacturing process of the coil unit [Diagram 5] 1 is a diagram showing the coil unit 100 during its manufacturing process. [Figure 6] 4 is a cross-sectional view of a coil unit according to another embodiment; [Figure 7] 4 is a cross-sectional view of a coil unit according to another embodiment; [Figure 8] 4 is a cross-sectional view of a coil unit according to another embodiment; DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0013] Hereinafter, an embodiment of the coil unit will be described with reference to the drawings. As shown in Fig. 1, the coil unit 100 is used as a non-contact power supply device that supplies power to an object in a non-contact manner. In the non-contact power supply device, a power receiving coil unit 100 and a power transmitting coil unit 100 are used, and power is supplied to the object in a non-contact state by utilizing electromagnetic induction that generates an electromotive force in the power receiving coil unit 100 due to a magnetic field generated in the power transmitting coil unit 100.

[0014] FIG. 1 shows an example in which a goods transport vehicle V equipped with a power storage device 9v is being charged at a charging station S.

[0015] The article transport vehicle V is an automatic guided vehicle (AGV) configured to automatically transport articles (not shown). The article transport vehicle V includes a power-receiving coil unit 100 electrically connected to a power storage device 9v.

[0016] The charging station S is provided with a power transmission coil unit 100 electrically connected to a power source 9s. Although detailed illustration is omitted, the power source 9s is configured as, for example, a high-frequency power supply device connected to a commercial power source.

[0017] The coil unit 100 on the power transmission side generates a magnetic field using power from the power source 9s. The coil unit 100 on the power reception side generates an electromotive force using the magnetic field generated on the power transmission side. The power generated by the electromotive force is stored in the power storage device 9v and is used for the operation of the article transport vehicle V.

[0018] In this manner, the coil unit 100 is electrically connected to the target portion 9. The coil unit 100 on the power receiving side is electrically connected to a power storage device 9v as the target portion 9, and the coil unit 100 on the power transmitting side is electrically connected to a power source 9s as the target portion 9. The coil unit 100 on the power transmitting side and the coil unit 100 on the power receiving side have the same configuration. The detailed configuration of the coil unit 100 will be described below.

[0019] 2 and 3, the coil unit 100 includes a support plate 1, a coil 2 arranged along a support surface F1 of the support plate 1, and molded resin 3. The coil unit 100 further includes a core 5 made of a magnetic material. The coil unit 100 also includes a cover 6 that covers the coil 2, the core 5, and the molded resin 3. The cover 6 is connected to the support plate 1, and an inner-cover space 60 is formed between the support plate 1 and the cover 6. The coil 2, the core 5, and the molded resin 3 are arranged in the inner-cover space 60.

[0020] In the following, a specific direction along the support surface F1 of the support plate 1 is referred to as a "first direction X", and a direction perpendicular to the first direction X when viewed in the normal direction along the normal direction of the support surface F1 is referred to as a "second direction Y". As shown in FIG. 2, in this example, the support plate 1 is formed in a rectangular shape (including a shape that is approximately rectangular overall) when viewed in the normal direction, and the direction along the long side is referred to as the first direction X. Note that FIG. 2 shows the coil unit 100 when viewed in the normal direction. FIG. 3 shows a cross-sectional view taken along the III-III cross section in FIG. 2.

[0021] The support plate 1 supports the coil 2, the core 5, and the molded resin 3 on a support surface F1. In this embodiment, the support plate 1 is made of metal. For example, the support plate 1 is made of an aluminum plate.

[0022] In this embodiment, the support plate 1 includes a metal plate member 10 (for example, an aluminum plate) and an insulating sheet 11 (electrically insulating sheet).

[0023] A fixing member 4, which will be described later, is fixed to the support plate 1. The support plate 1 has a mounting hole 12 to which the fixing member 4 is attached. In this example, the mounting hole 12 is formed with a female screw 12a.

[0024] The insulating sheet 11 is attached to the surface of the plate member 10. In this example, the surface of the insulating sheet 11 attached to the plate member 10 serves as a supporting surface F1. That is, the coil 2, the core 5, and the molded resin 3 are supported on the surface of the insulating sheet 11 (supporting surface F1).

[0025] The coil 2 includes a first coil body 21 and a second coil body 22 each formed in a ring shape when viewed in a normal direction along the normal direction of the support surface F1, and arranged adjacent to each other in a first direction X, which is a specific direction along the support surface F1. In this embodiment, each of the first coil body 21 and the second coil body 22 is formed by winding an insulating coated linear conductor in a ring shape. A portion of each of the first coil body 21 and the second coil body 22 is drawn out to the outside of the cover 6 and electrically connected to the target unit 9 (the power storage device 9v on the power receiving side and the power source 9s on the power transmitting side).

[0026] As shown in Figure 2, in this embodiment, the center position of the first coil body 21 when viewed in the normal direction (hereinafter referred to as the "first center position C1") and the center position of the second coil body 22 (hereinafter referred to as the "second center position C2") are located at the same position in the second direction Y.

[0027] The first center position C1 is a position set in the center of the area surrounded by the outer edge of the first coil body 21 when viewed in the normal direction. For example, the first center position C1 can be the center of gravity of the area surrounded by the outer edge of the first coil body 21 when viewed in the normal direction (the center of gravity of the figure when the area is viewed as a figure). Although different from the illustration, for example, the first center position C1 can be the center position or center of gravity of the gap portion surrounded by the first coil body 21 when viewed in the normal direction. The second center position C2 is a position set in the center of the area surrounded by the outer edge of the second coil body 22 when viewed in the normal direction. For example, the second center position C2 can be the center of gravity of the area surrounded by the outer edge of the second coil body 22 when viewed in the normal direction (the center of gravity of the figure when the area is viewed as a figure). Although different from the illustration, for example, the second center position C2 can be the center position or the center of gravity position of the gap portion surrounded by the second coil body 22 when viewed in the normal direction.

[0028] In this embodiment, an outer edge portion 21E of the first coil body 21 (hereinafter referred to as "first outer edge portion 21E") and an outer edge portion 22E of the second coil body 22 (hereinafter referred to as "second outer edge portion 22E") are disposed at the same position in the second direction Y when viewed in the normal direction. The first outer edge portion 21E is an end portion of the first coil body 21 in the second direction Y. The second outer edge portion 22E is an end portion of the second coil body 22 in the second direction Y. The end portion of the first coil body 21 in the second direction Y (first outer edge portion 21E) and the end portion of the second coil body 22 in the second direction Y (second outer edge portion 22E) are disposed at the same position in the second direction Y. As a result, the first coil body 21 and the second coil body 22 are contained within the same region in the second direction Y. With the above-described configuration, the sizes of the first coil body 21 and the second coil body 22 are ensured, while the entire coil unit 100 can be easily made compact.

[0029] The first coil body 21 and the second coil body 22 each have, in a portion facing each other in the first direction X, curved portions (210, 220) formed so as to move toward the side that moves away from each other in the first direction X as they move toward the outside in the second direction Y. In this embodiment, the first coil body 21 and the second coil body 22 each have, in a portion facing each other in the first direction X, straight portions (211, 221) formed continuously with the curved portions (210, 220) and extending linearly along the second direction Y. The curved portions (210, 220) are portions formed in a curved shape when viewed in the normal direction. The straight portions (211, 221) are portions formed in a linear shape when viewed in the normal direction. Hereinafter, the curved portion 210 of the first coil body 21 will be referred to as the "first curved portion 210", and the curved portion 220 of the second coil body 22 will be referred to as the "second curved portion 220". Moreover, straight portion 211 of first coil body 21 will be referred to as "first straight portion 211", and straight portion 221 of second coil body 22 will be referred to as "second straight portion 221".

[0030] The first straight portion 211 and the second straight portion 221 face each other in the first direction X. The first straight portion 211 is a portion of the first coil body 21 that is disposed closest to the second coil body 22. The second straight portion 221 is a portion of the second coil body 22 that is disposed closest to the first coil body 21. In this embodiment, the first straight portion 211 and the second straight portion 221 are disposed so as to contact each other in the first direction X. This makes it possible to ensure a wide area occupied by the coil 2 in the cover interior space 60.

[0031] In this embodiment, a pair of first curved portions 210 are disposed on both sides of the first straight portion 211 in the second direction Y. Each of the pair of first curved portions 210 is disposed between the first straight portion 211 and the first outer edge portion 21E. In this example, the first coil body 21 has a shape that is line-symmetrical with respect to a virtual line L that connects the first center position C1 and the second center position C2 when viewed in the normal direction. Therefore, a part of the first straight portion 211, the first curved portion 210, and the first outer edge portion 21E are disposed on both sides of the virtual line L in the second direction Y.

[0032] In this embodiment, a pair of second curved portions 220 are disposed on both sides of the second straight portion 221 in the second direction Y. Each of the pair of second curved portions 220 is disposed between the second straight portion 221 and the second outer edge portion 22E. In this example, the second coil body 22 has a shape that is line-symmetrical with respect to a virtual line L that connects the first center position C1 and the second center position C2 when viewed in the normal direction. Therefore, a part of the second straight portion 221, the second curved portion 220, and the second outer edge portion 22E are disposed on both sides of the virtual line L in the second direction Y.

[0033] The first curved portion 210 is formed so that the closer the portion is to the second coil body 22, the further away it is from the outer edge of the support plate 1 (and cover 6) in the second direction Y. In other words, the closer the portion is to the second coil body 22, the closer it is to the outer edge of the support plate 1 (and cover 6) in the second direction Y.

[0034] In this embodiment, the first curved portion 210 includes a tapered section 210a that is continuous with the first outer edge portion 21E and inclined toward the center side (virtual line L) in the second direction Y as it approaches the second coil body 22, and an arc section 210b that is continuous with the tapered section 210a and is formed in an arc shape when viewed in the normal direction. The arc section 210b is continuous with the first straight portion 211 at an end opposite to the end that is continuous with the tapered section 210a. The arc section 210b is formed in an arc shape with the center of the arc on the side of the first center position C1.

[0035] The second curved portion 220 is formed so that the closer the portion is to the first coil body 21, the further away it is from the outer edge of the support plate 1 (and cover 6) in the second direction Y. In other words, the further away the portion is from the first coil body 21, the closer the portion is to the outer edge of the support plate 1 (and cover 6) in the second direction Y.

[0036] In this embodiment, the second curved portion 220 includes a tapered section 220a that is continuous with the second outer edge portion 22E and inclined toward the center side (virtual line L) in the second direction Y as it approaches the first coil body 21, and an arc section 220b that is continuous with the tapered section 220a and formed in an arc shape when viewed in the normal direction. The arc section 220b is continuous with the second straight portion 221 at an end opposite to the end that is continuous with the tapered section 220a. The arc section 220b is formed in an arc shape with the center of the arc on the side of the second center position C2.

[0037] By arranging the first bending portion 210 and the second bending portion 220 configured as described above facing each other in the first direction X, a coil non-placement space in which the coil 2 is not placed (hereinafter referred to as "coil non-placement space Ga in the first direction X") is formed between the first bending portion 210 and the second bending portion 220 in the first direction X.

[0038] The first coil body 21 is formed by winding a linear conductor in a ring shape as viewed in the normal direction so that the dimension in the normal direction increases as the number of turns of the linear conductor increases. In other words, the first coil body 21 is formed by stacking the linear conductor wound in a ring shape in the normal direction. As shown in FIG. 5, in this embodiment, the first coil body 21 is formed so that the dimension in the normal direction decreases as the portion approaches the second coil body 22. As a result, in the portion of the first coil body 21 close to the second coil body 22, a coil non-arrangement space (hereinafter referred to as "coil non-arrangement space Gb in the normal direction") in which the coil 2 is not arranged in the normal direction is formed. In this example, in the region on the second coil body 22 side of the first center position C1, each part in the normal direction of the linear conductor constituting the first coil body 21 is offset toward the second coil body 22 side in a hierarchical manner. As a result, the first coil body 21 is formed so that the dimension in the normal direction decreases as the portion approaches the second coil body 22. 5 shows the coil unit 100 in the process of being manufactured, the arrangement of the support plate 1, the coil 2, the core 5, and the fixing member 4 in the finished coil unit 100 is as shown in FIG.

[0039] The second coil body 22 is formed by winding a linear conductor in a ring shape as viewed in the normal direction so that the dimension in the normal direction increases as the number of turns of the linear conductor increases. In other words, the second coil body 22 is formed by stacking the linear conductor wound in a ring shape in the normal direction. In this embodiment, the second coil body 22 is formed so that the dimension in the normal direction decreases as the portion approaches the first coil body 21. As a result, a coil non-arrangement space (coil non-arrangement space Gb in the normal direction) in which the coil 2 is not arranged in the normal direction is formed in the portion of the second coil body 22 that is closer to the first coil body 21. In this example, in the region on the first coil body 21 side than the second center position C2, each part in the normal direction of the linear conductor constituting the second coil body 22 is offset toward the first coil body 21 side in a hierarchical manner. As a result, the second coil body 22 is formed so that the dimension in the normal direction decreases as the portion approaches the first coil body 21.

[0040] In this embodiment, a core 5 made of a magnetic material is disposed between the first coil body 21 and the second coil body 22 and the support plate 1. For example, the core 5 is made of a magnetic material made of ferrite. The core 5 may be made of a single magnetic material. Alternatively, one core 5 may be formed by combining a plurality of magnetic materials.

[0041] In this embodiment, the core 5 is continuously disposed in the first direction X so as to overlap both the first central position C1 and the second central position C2 when viewed in the normal direction. The core 5 includes an overlapping portion 50 that overlaps with the coil 2 when viewed in the normal direction, and a non-overlapping portion (51, 52) that does not overlap with the coil 2 when viewed in the normal direction.

[0042] The overlapping portion 50 is the center of the core 5 in the first direction X. When viewed in the normal direction, the overlapping portion 50 overlaps both the first coil body 21 and the second coil body 22. As described above, in this embodiment, a non-coil space Gb in the normal direction is formed in the portion where the first coil body 21 and the second coil body 22 are close to each other (see FIG. 5). The overlapping portion 50 is disposed in the non-coil space Gb in the normal direction.

[0043] The non-overlapping portion (51, 52) is both ends of the core 5 in the first direction X. The non-overlapping portion (51, 52) includes a first non-overlapping portion 51 disposed closer to the first coil body 21 in the first direction X than the overlapping portion 50, and a second non-overlapping portion 52 disposed closer to the second coil body 22 in the first direction X than the overlapping portion 50. In this embodiment, the first non-overlapping portion 51 is disposed outside the first direction X than the first center position C1. Alternatively, a part of the first non-overlapping portion 51 may be disposed outside the first direction X than the first center position C1. Moreover, the second non-overlapping portion 52 is disposed outside the second center position C2 in the first direction X. Alternatively, a part of the second non-overlapping portion 52 may be disposed outside the second center position C2 in the first direction X.

[0044] 2 and 3, in this embodiment, the core 5 is disposed so as to be in contact with the support surface F1. This makes it easier to transfer heat generated from the coil 2 to the support plate 1 via the core 5, which makes it easier to improve the heat dissipation of the coil unit 100. In this example, the entire surface of the core 5 facing the support surface F1 is in contact with the support surface F1. This can further enhance the above-mentioned effect.

[0045] In the coil unit 100 according to the present disclosure, the fixing member 4 is disposed between the curved portion (first curved portion 210) of the first coil body 21 and the curved portion (second curved portion 220) of the second coil body 22 in the first direction X. The fixing member 4 is a member for fixing the molded resin 3 and the support plate 1. As described above, a coil non-arrangement space (coil non-arrangement space Ga in the first direction X) in which the coil 2 is not arranged is formed between the first curved portion 210 and the second curved portion 220 in the first direction X. The fixing member 4 is disposed in the coil non-arrangement space Ga in the first direction X. The fixing member 4 is configured using a non-magnetic material such as SUS, aluminum, synthetic resin, etc. This makes it difficult for the fixing member 4 to generate heat when a magnetic field is generated. In addition, the fixing member 4 can be disposed while minimizing the effect on the magnetic field generated by the coil 2.

[0046] In this embodiment, a plurality of fixed members 4 are provided. The plurality of fixed members 4 are arranged line-symmetrically with respect to a virtual line L connecting the first central position C1 and the second central position C2 when viewed in the normal direction. The plurality of fixed members 4 are arranged in the coil non-placement space Ga in the first direction X. In this example, two fixed members 4 are arranged line-symmetrically with respect to the virtual line L when viewed in the normal direction.

[0047] The fixed member 4 has a fixed portion 41 fixed to the support plate 1, and an extension portion 42 arranged to extend from the fixed portion 41 toward the side on which the first coil body 21 and the second coil body 22 are arranged relative to the support surface F1.

[0048] In this embodiment, the fixing portion 41 includes a fixed side male threaded portion 411 arranged on the side of the fixing member 4 facing the support plate 1. A male thread 411a is formed in the fixed side male threaded portion 411. The male thread 411a of the fixed side male threaded portion 411 is screwed into the female thread 12a formed in the mounting hole 12 of the support plate 1 and fixed. That is, in this embodiment, the male thread 411a formed in the fixing portion 41 is screwed into the female thread 12a formed in the support plate 1 and fixed.

[0049] The extending end 42E, which is the end of the extending portion 42, is disposed between the support plate 1 and the cover 6. In other words, the extending end 42E is disposed at a position separated from the cover 6 in the cover inner space 60, and does not penetrate the cover 6 in the normal direction.

[0050] In this embodiment, the extension portion 42 includes a locking portion 420 that is locked to the molded resin 3. The locking portion 420 is disposed between the fixed side male screw portion 411 and the extension end portion 42E. Therefore, the locking portion 420 is disposed in the cover inner space 60 and embedded in the molded resin 3.

[0051] In this embodiment, the fixing member 4 is a bolt. In the illustrated example, the fixing member 4 is configured using a stud bolt having threaded portions at both ends. The above-mentioned fixed side male thread portion 411 is formed at one end of the fixing member 4, and the extension side male thread portion 421 is formed at the other end of the fixing member 4. In this example, the extension side male thread portion 421 constitutes the locking portion 420. The male thread 421a formed on the extension side male thread portion 421 generates friction with the molded resin 3, so that the extension side male thread portion 421 (locking portion 420) is locked to the molded resin 3.

[0052] The molded resin 3 is formed by drying and hardening an adhesive resin. The molded resin 3 is formed in the space 60 inside the cover. The first coil body 21, the second coil body 22, and the extension 42 of the fixing member 4 are embedded in the molded resin 3, and the molded resin 3 and the support plate 1 are integrally joined. The core 5 is also embedded in the molded resin 3. It is preferable that the molded resin 3 and the cover 6 are arranged so as not to contact each other. In other words, it is preferable that a small gap (for example, 1 mm to 2 mm) is formed between the molded resin 3 and the cover 6. This makes it possible to assemble the molded resin 3 and the cover 6 without interfering with each other, improving the ease of assembly of the coil unit 100.

[0053] As described above, the fixing portion 41 of the fixing member 4 is fixed to the support plate 1. In addition, since the extension portion 42 of the fixing member 4 is embedded in the molded resin 3, the molded resin 3 and the support plate 1 can be appropriately integrated. Therefore, the first coil body 21, the second coil body 22, and the core 5 embedded in the molded resin 3 can be appropriately integrated with the support plate 1. According to the coil unit 100 of the present disclosure, the fixing member 4 is disposed in the dead space (coil non-arrangement space Ga in the first direction X) between the curved portion (first curved portion 210) of the first coil body 21 and the curved portion (second curved portion 220) of the second coil body 22 in the first direction X. Therefore, the molded resin 3 and the support plate 1 can be appropriately integrated while suppressing an increase in the dimensions of the coil unit 100.

[0054] Next, a method for manufacturing the above-mentioned coil unit 100, i.e., the coil unit 100 including the support plate 1, the coil 2, and the molded resin 3, will be described mainly with reference to Fig. 4 and Fig. 5. Fig. 4 is a flowchart showing the manufacturing process of the coil unit 100. Fig. 5 shows the coil unit 100 in the middle of its manufacturing process, and illustrates a state prior to a resin supplying process P6 in which resin is supplied into the interior of the mold 8 in which the coil 2, the core 5, and the fixing member 4 are arranged.

[0055] As shown in Fig. 4, the manufacturing method of the coil unit 100 according to this embodiment includes a support plate preparation step P1, a mold preparation step P2, a coil accommodation step P3, a core arrangement step P4, a fixing member arrangement step P5, a resin supply step P6, a mold removal step P7, and a cover attachment step P8. In this embodiment, each step is performed in the order shown in Fig. 4. In this embodiment, the coil arrangement step P9 includes the coil accommodation step P3 and the fixing member arrangement step P5.

[0056] The support plate preparation process P1 is a process of preparing the support plate 1. In this embodiment, the support plate preparation process P1 includes a process of attaching an insulating sheet 11 to a plate member 10 to form the support plate 1. The support plate preparation process P1 may also include a process of attaching a fixing member 4 to the support plate 1. In this case, in the support plate preparation process P1, the support plate 1 to which the fixing member 4 is attached is prepared.

[0057] The mold preparation step P2 is a step of preparing a mold 8 (see FIG. 5). The mold 8 has an internal space into which resin is supplied and into which the molding resin 3 is formed. In this internal space, the coil 2, the core 5, and the fixing member 4 are arranged by the coil accommodating step P3, the core arranging step P4, and the fixing member arranging step P5.

[0058] The coil arrangement step P9 is a step of arranging the coil 2 including the first coil body 21 and the second coil body 22 along the support surface F1 of the support plate 1. In the coil arrangement step P9, the first coil body 21 and the second coil body 22 are each formed into an annular shape when viewed in the normal direction along the normal direction of the support surface F1, and the first coil body 21 and the second coil body 22 are arranged so as to be adjacent to each other in a first direction X, which is a specific direction along the support surface F1 (see also FIG. 2). In the coil arrangement step P9, the coil 2 is arranged along the support surface F1 of the support plate 1 so as to form the curved portions (210, 220) in the portions of the first coil body 21 and the second coil body 22 that face each other in the first direction X and that are formed so as to move toward the side that moves away from each other in the first direction X as they move toward the outside in the second direction Y.

[0059] In this embodiment, the coil arrangement step P9 includes a coil accommodation step P3 and a fixing member arrangement step P5. The coil accommodation step P3 is a step of accommodating the coil 2 in the internal space of the mold 8. In this embodiment, in the coil accommodation step P3, the coil 2 is accommodated in the internal space of the mold 8 in a state in which the support plate 1 is separated from the mold 8. Then, in the fixing member arrangement step P5 executed after the coil accommodation step P3, the support plate 1 is arranged with respect to the mold 8 so that the coil 2 is along the support surface F1. In the coil accommodation step P3, after the fixing member arrangement step P5 is executed, the coil 2 is accommodated in the internal space of the mold 8 so that the first coil body 21 and the second coil body 22, each formed in an annular shape when viewed in the normal direction, are arranged adjacent to each other in the first direction X.

[0060] The core arrangement step P4 is a step of arranging the cores 5. In the core arrangement step P4 according to the present embodiment, the cores 5 are continuously arranged in the first direction X so as to overlap both the center position (first center position C1) of the first coil body 21 and the center position (second center position C2) of the second coil body 22 when viewed in the normal direction (see also FIG. 2). In addition, in the core arrangement step P4, the core 5 is arranged so that the core 5 has an overlapping portion 50 that overlaps with the coil 2 when viewed in the normal direction and a non-overlapping portion (51, 52) that does not overlap with the coil 2 when viewed in the normal direction.

[0061] The fixing member arrangement process P5 is a process of arranging the fixing member 4. In this embodiment, in the fixing member arrangement process P5, the fixing member 4 and the support plate 1 are arranged relative to the mold 8 so that the fixing member 4 is arranged as described below. The fixing member arrangement process P5 is performed at least before the resin supplying process P6. In this embodiment, the fixing member arrangement process P5 is performed before the resin supplying process P6 and after the coil accommodating process P3. In the fixing member arrangement process P5, the fixing member 4 is arranged between the curved portion (first curved portion 210) of the first coil body 21 and the curved portion (second curved portion 220) of the second coil body 22 in the first direction X, and the fixing portion 41 of the fixing member 4 is fixed to the support plate 1, and the extension portion 42 extending from the fixing portion 41 is arranged so as to extend toward the side where the first coil body 21 and the second coil body 22 are arranged with respect to the support surface F1. As described above, in the support plate preparation process P1, a support plate 1 having a fixing member 4 attached thereto may be prepared, in which case the process of "fixing the fixing portion 41 of the fixing member 4 to the support plate 1" in the fixing member placement process P5 is included in the support plate preparation process P1.

[0062] In the fixing member arranging step P5 according to this embodiment, the fixing member 4 is arranged so that the extending portion 42 (extending end portion 42E) of the fixing member 4 is located between the support plate 1 and the inner wall of the mold 8 (see FIG. 5). In other words, in the fixing member arranging step P5, the fixing member 4 is arranged so that the extending end portion 42E is arranged away from the inner wall of the mold 8.

[0063] By carrying out the coil accommodating step P3, the core arranging step P4, and the fixing member arranging step P5, the coil 2, the core 5, and the fixing member 4 are arranged in the internal space of the mold 8 as shown in FIG.

[0064] The resin supplying step P6 is a step executed after the coil arrangement step P9 and the fixing member arrangement step P5. In this embodiment, since the fixing member arrangement step P5 is included in the coil arrangement step P9, "after the coil arrangement step P9 and the fixing member arrangement step P5" can be rephrased as "after the coil arrangement step P9". The resin supplying step P6 according to this embodiment is executed after the core arrangement step P4 in addition to the coil arrangement step P9 and the fixing member arrangement step P5. In the resin supplying step P6, resin is supplied to an area adjacent to the support surface F1 of the support plate 1 so that the first coil body 21, the second coil body 22, and the extension part 42 of the fixing member 4 are embedded in the resin. In the resin supplying step P6 according to this embodiment, resin is supplied to an area adjacent to the support surface F1 of the support plate 1 so that the core 5 is also embedded in the resin. The resin supplying step P6 is executed by using a fluid adhesive resin as the resin and pouring the resin from the supply port 80 of the mold 8 into the internal space of the mold 8.

[0065] The mold removal process P7 is a process of removing the mold 8 from the support plate 1. In the mold removal process P7, the mold 8 is removed from the support plate 1 after the resin supplied to the internal space of the mold 8 has hardened.

[0066] The cover attachment process P8 is a process of attaching the cover 6 to the support plate 1. In the cover attachment process P8, the cover 6 is attached to the support plate 1 so as to cover the molding resin 3 in which the coil 2, the core 5, and the fixing members 4 are embedded.

[0067] In the manufacturing method of the coil unit 100, at least the fixing member arrangement step P5 is followed by the resin supply step P6. That is, the fixing member 4 is fixed to the support plate 1 by the fixing portion 41 by performing the fixing member arrangement step P5, and then the resin supply step P6 is performed to embed the extension portion 42 of the fixing member 4 in the resin, so that the molded resin 3 formed by the hardened resin can be appropriately integrated with the support plate 1. That is, as shown in FIG. 3, the resin is filled around the locking portion 420 formed in the extension portion 42, and the resin is deformed to match the shape of the locking portion 420 and hardened, so that the locking portion 420 is locked to the molded resin 3 after hardening. As a result, the fixing member 4 and the molded resin 3 are appropriately fixed. And the fixing member 4 is also fixed to the support plate 1 by the fixing portion 41. Therefore, the support plate 1 and the molded resin 3 can be appropriately fixed via the fixing member 4.

[0068] Other embodiments Next, other embodiments of the coil unit and the method for manufacturing the coil unit will be described.

[0069] (1) In the above embodiment, an example has been described in which the fixing member 4 is configured using a stud bolt having threaded portions at both ends, and an extended side male threaded portion 421 formed at one end of the stud bolt constitutes the locking portion 420 that is locked to the molded resin 3. However, the present invention is not limited to such an example, and for example, as shown in FIG. 6, the fixing member may be configured using a bolt 4A having a head 420A, and the head 420A of the bolt 4A may constitute the locking portion 420. The head 420A of the bolt 4A becomes a hook and is locked to the molded resin 3. Therefore, even with this configuration, the support plate 1 and the molded resin 3 can be appropriately fixed via the bolt 4A. In addition, as another example, as shown in FIG. 7, the fixing member may be configured using a rod-shaped member 4B having a bent portion 420B that is bent so as to intersect with the normal direction, and the bent portion 420B of the rod-shaped member 4B may constitute the locking portion 420. The bent portion 420B of the rod-shaped member 4B becomes a hook and is locked to the molded resin 3. Therefore, even with this configuration, the support plate 1 and the molding resin 3 can be appropriately fixed together via the rod-shaped members 4B.

[0070] (2) In the above embodiment, an example has been described in which the fixing member 4 is disposed between the curved portion (first curved portion 210) of the first coil body 21 and the curved portion (second curved portion 220) of the second coil body 22 in the first direction X. However, the fixing member 4 may be disposed at a location other than between the first curved portion 210 and the second curved portion 220 in the first direction X. For example, in the cover interior space 60, when there is a dead space on the outside of the first direction X with respect to the first coil body 21, the fixing member 4 may be disposed on the outside of the first direction X with respect to the first coil body 21. In addition, in the cover interior space 60, when there is a dead space on the outside of the first direction X with respect to the second coil body 22, the fixing member 4 may be disposed on the outside of the first direction X with respect to the second coil body 22.

[0071] (3) In the above embodiment, an example has been described in which the coil accommodating step P3 is followed by the core arranging step P4, and the fixing member arranging step P5 is performed after the core arranging step P4. However, the present invention is not limited to this example, and the order in which the coil accommodating step P3, the fixing member arranging step P5, and the core arranging step P4 are performed can be determined arbitrarily. In addition, the coil accommodating step P3, the fixing member arranging step P5, and the core arranging step P4 may be performed simultaneously.

[0072] (4) In the above embodiment, an example has been described in which the coil arrangement step P9 includes the coil accommodation step P3 and the fixing member arrangement step P5. However, the present invention is not limited to such an example, and the coil arrangement step P9 may not include the fixing member arrangement step P5. For example, the coil 2 including the first coil body 21 and the second coil body 22 may be arranged along the support surface F1 of the support plate 1 by one step constituting the coil arrangement step P9. In this case, it is preferable to perform the core arrangement step P4 before the coil arrangement step P9 so as to make it easier to arrange the core 5.

[0073] (5) In the above embodiment, an example has been described in which the fixing member arrangement step P5 is performed after the coil accommodation step P3. In the fixing member arrangement step P5, the fixing member 4 is arranged between the curved portion (first curved portion 210) of the first coil body 21 and the curved portion (second curved portion 220) of the second coil body 22 in the first direction X, the fixing portion 41 of the fixing member 4 is fixed to the support plate 1, and the extension portion 42 extending from the fixing portion 41 is arranged to extend toward the side where the first coil body 21 and the second coil body 22 are arranged with respect to the support surface F1. However, the present invention is not limited to such an example, and the fixing member arrangement step P5 may be performed before the coil accommodation step P3. In this case, the coil accommodation step P3 is performed after the fixing member arrangement step P5. Then, in this coil accommodating process P3, the coil 2 is arranged so that the fixed member 4 is sandwiched in the first direction X between the curved portion (first curved portion 210) of the first coil body 21 and the curved portion (second curved portion 220) of the second coil body 22. Even in this case, the fixed member 4 is ultimately arranged between the curved portion (first curved portion 210) of the first coil body 21 and the curved portion (second curved portion 220) of the second coil body 22 in the first direction X.

[0074] (6) In the above embodiment, an example has been described in which the male thread 411a formed on the fixing portion 41 is screwed into the female thread 12a of the mounting hole 12 formed in the support plate 1 and fixed, thereby fixing the fixing member 4 to the support plate 1. However, the present invention is not limited to such an example, and the fixing member 4 may be fixed to the support plate 1 by pressing the fixing portion 41 into the mounting hole 12. In this case, the male thread 411a may not be formed on the fixing portion 41, and the female thread 12a may not be formed in the mounting hole 12. Furthermore, as another example of pressing the fixing member 4 into the support plate 1, as shown in FIG. 8, a fixing member 4C formed of a press-fit type stud bolt may be used and the fixing member 4C may be pressed into the through hole 13 formed in the support plate 1 from the side opposite to the support surface F1 of the support plate 1. In this case, it is preferable to press the fixing member 4C so that the head of the fixing member 4C does not protrude from the surface of the support plate 1 opposite to the support surface F1. In the example shown in FIG. 8, the threaded portion 420C of the fixing member 4C constitutes the locking portion 420.

[0075] (7) In the above embodiment, an example has been described in which the first center position C1 of the first coil body 21 and the second center position C2 of the second coil body 22, as viewed in the normal direction, are disposed at the same position in the second direction Y, and the first outer edge portion 21E of the first coil body 21 and the second outer edge portion 22E of the second coil body 22, as viewed in the normal direction, are disposed at the same position in the second direction Y. However, without being limited to such an example, the first center position C1 of the first coil body 21 and the second center position C2 of the second coil body 22 may be disposed at positions shifted from each other in the second direction Y. Furthermore, the first outer edge portion 21E of the first coil body 21 and the second outer edge portion 22E of the second coil body 22 may be disposed at positions shifted from each other in the second direction Y.

[0076] (8) In the above embodiment, an example has been described in which the multiple fixing members 4 are arranged line-symmetrically with respect to the virtual line L connecting the first central position C1 and the second central position C2 in the normal direction view. However, the multiple fixing members 4 do not have to be arranged line-symmetrically with respect to the virtual line L. In other words, the multiple fixing members 4 may be arranged at positions that are different distances from the virtual line L in the second direction Y, or may be arranged at positions that are shifted from each other in the first direction X.

[0077] (9) In the above embodiment, an example has been described in which the core 5 is continuously arranged in the first direction X so as to overlap both the first center position C1 and the second center position C2 when viewed in the normal direction. However, the present invention is not limited to this example, and the core 5 may be formed using a plurality of magnetic bodies and may be arranged discontinuously in the first direction X.

[0078] (10) In the above embodiment, an example has been described in which the coil unit 100 is used for charging an article transport vehicle V. Examples of objects to be charged using the coil unit 100 include various types of article transport vehicles V equipped with a power storage device 9v, and for example, a ceiling transport vehicle that travels along a travel path set near the ceiling may be the object.

[0079] (11) The configurations disclosed in the above-described embodiments can be applied in combination with configurations disclosed in other embodiments, as long as no contradiction occurs. As for other configurations, the embodiments disclosed in this specification are merely examples in all respects. Therefore, various modifications can be made as appropriate within the scope of the present disclosure.

[0080] [Summary of the above embodiment] The above-described coil unit and a method for manufacturing the coil unit will now be described.

[0081] A coil unit including a support plate, a coil disposed along a support surface of the support plate, and a mold resin, The coil includes a first coil body and a second coil body that are each formed in an annular shape when viewed in a normal direction along the normal direction of the support surface, and that are arranged adjacent to each other in a first direction that is a specific direction along the support surface, A direction perpendicular to the first direction when viewed in the normal direction is defined as a second direction, each of the first coil body and the second coil body includes a curved portion formed in a portion facing each other in the first direction so as to extend toward an outer side in the second direction and toward a side that separates from each other in the first direction; a fixing member is disposed between the curved portion of the first coil body and the curved portion of the second coil body in the first direction; the fixing member has a fixing portion fixed to the support plate and an extending portion arranged to extend from the fixing portion to a side where the first coil body and the second coil body are arranged with respect to the support surface, The first coil body, the second coil body, and the extension portion are embedded in the molding resin, and the molding resin and the support plate are integrally joined together.

[0082] When a space forming member for forming a space in which a coil or molded resin is arranged is used as in the past, each member including the space forming member is joined to the molded resin, so that each member can be properly integrated. However, when forming a coil unit without using such a space forming member, it is necessary to properly integrate the molded resin and the member in contact with the molded resin. According to this configuration, since the fixing portion of the fixing member is fixed to the support plate and the extension portion of the fixing member is embedded in the molded resin, the molded resin and the support plate can be properly integrated, and thus the first coil body and the second coil body embedded in the molded resin can be properly integrated with the support plate. Furthermore, according to this configuration, since the fixing member is disposed in the dead space between the curved portion of the first coil body and the curved portion of the second coil body in the first direction, the molded resin and the support plate can be properly integrated while suppressing the expansion of the dimensions of the coil unit. As described above, according to this configuration, each member constituting the coil unit can be properly integrated, and a coil unit that is easy to reduce costs can be realized.

[0083] Each of the first coil body and the second coil body is formed by winding an insulating coated linear conductor into a ring shape, The support plate is made of metal, The fixing member is a bolt, It is preferable that a male thread formed on the fixing portion is screwed into a female thread formed on the support plate and fixed thereto.

[0084] According to this configuration, since the first coil body and the second coil body are made of an insulating-coated linear conductor, electrical insulation can be easily ensured even when the coil body is arranged along a metal support plate. This reduces the need for separate insulating materials, etc., and makes it easy to reduce manufacturing costs and further the cost of the coil unit. In addition, since the male thread formed on the fixing portion and the female thread formed on the support plate are screwed together, the fixing member can be easily and appropriately fixed to the support plate.

[0085] a center position of the first coil body and a center position of the second coil body when viewed in the normal direction are disposed at the same position in the second direction, It is preferable that an outer edge portion of the first coil body and an outer edge portion of the second coil body when viewed in the normal direction are disposed at the same position in the second direction.

[0086] According to this configuration, it is easy to reduce the size of the entire coil unit while ensuring the sizes of the first coil body and the second coil body.

[0087] A plurality of the fixing members are provided, It is preferable that the multiple fixing members are arranged symmetrically with respect to an imaginary line connecting a central position of the first coil body and a central position of the second coil body when viewed in the normal direction.

[0088] According to this configuration, the position at which the molding resin is fixed to the support plate can be easily made uniform with respect to the center positions of the first coil body and the second coil body, and therefore it is easy to ensure the fixing strength of the molding resin to the support plate.

[0089] a core made of a magnetic material is disposed between the first coil body, the second coil body and the support plate; the core is disposed continuously in the first direction so as to overlap both a center position of the first coil body and a center position of the second coil body when viewed in the normal direction, The core is preferably arranged in contact with the support surface.

[0090] This configuration makes it easier to release a large amount of magnetic flux to the side opposite the support plate. Also, heat generated by the coil can be easily transferred to the support plate via the core, which makes it easier to improve the heat dissipation of the coil unit.

[0091] A method for manufacturing a coil unit including a support plate, a coil, and a molding resin, comprising the steps of: a coil arrangement step of arranging the coil including a first coil body and a second coil body along a support surface of the support plate, a fixing member arrangement step of arranging a fixing member, and a resin supply step of supplying a resin, which is performed after the coil arrangement step and the fixing member arrangement step, In the coil arrangement step, the first coil body and the second coil body are each formed into an annular shape when viewed in a normal direction along the normal direction of the support surface, and the first coil body and the second coil body are arranged so as to be adjacent to each other in a first direction, which is a specific direction along the support surface; A direction perpendicular to the first direction when viewed in the normal direction is defined as a second direction, a curved portion is a portion of each of the first coil body and the second coil body that faces each other in the first direction and is formed so as to move toward a side that moves away from each other in the first direction as it moves toward the outside in the second direction, In the fixing member arrangement step, the fixing member is arranged between the curved portion of the first coil body and the curved portion of the second coil body in the first direction, a fixing portion of the fixing member is fixed to the support plate, and an extension portion extending from the fixing portion is arranged so as to extend on a side where the first coil body and the second coil body are arranged with respect to the support surface; In the resin supplying step, it is preferable that the resin is supplied to an area adjacent to the support surface of the support plate so that the first coil body, the second coil body, and the extension portion are embedded in the resin.

[0092] According to this configuration, the fixing member is fixed to the support plate by the fixing portion in the fixing member arrangement step, and then the extension portion of the fixing member is embedded in the resin in the resin supply step, so that the molded resin formed by the hardening of the resin can be appropriately integrated with the support plate. This allows the first coil body and the second coil body embedded in the molded resin to be appropriately integrated with the support plate. Furthermore, according to this configuration, the fixing member is arranged in the dead space between the curved portion of the first coil body and the curved portion of the second coil body in the first direction, so that the molded resin can be appropriately integrated with the support plate while suppressing an increase in the dimensions of the coil unit. As described above, according to this configuration, it is possible to realize a coil unit that can be appropriately integrated with each member constituting the coil unit and can easily reduce costs. [Industrial Applicability]

[0093] The technology disclosed herein can be utilized in a coil unit including a support plate, a coil arranged along the support surface of the support plate, and molding resin, and in a method for manufacturing the coil unit. [Explanation of symbols]

[0094] 100: Coil unit 1: Support plate F1: Support surface 12a: Female thread of support plate 2: Coil 21: First coil body C1: Center position of the first coil body 21E: Outer edge of the first coil body 210: Curved portion of first coil body 22: Second coil body C2: Center position of the second coil body 22E: Outer edge of second coil body 220: Curved portion of second coil body 3:Mold resin 4: Fixing material 41:Fixed part 411a: Male thread of fixed male thread part 42:Extending part 421a: Male thread of the extended male thread part 5: Core L: Virtual line P3: Coil placement process P5: Fixing parts placement process P6: Resin supply process X: 1st direction Y: Second direction

Claims

1. A coil unit including a support plate, a coil disposed along a support surface of the support plate, and a mold resin, The coil includes a first coil body and a second coil body that are each formed in an annular shape when viewed in a normal direction along the normal direction of the support surface, and that are arranged adjacent to each other in a first direction that is a specific direction along the support surface, A direction perpendicular to the first direction when viewed in the normal direction is defined as a second direction, Each of the first coil body and the second coil body includes a curved portion formed in a portion facing each other in the first direction so as to move toward a side that moves away from each other in the first direction as the curved portion moves toward an outer side in the second direction, a fixing member is disposed between the curved portion of the first coil body and the curved portion of the second coil body in the first direction; the fixing member has a fixing portion fixed to the support plate and an extending portion arranged to extend from the fixing portion to a side where the first coil body and the second coil body are arranged with respect to the support surface, the first coil body, the second coil body, and the extension portion are embedded in the molding resin, and the molding resin and the support plate are integrally joined.

2. Each of the first coil body and the second coil body is formed by winding an insulating coated linear conductor into a ring shape, The support plate is made of metal, The fixing member is a bolt, The coil unit according to claim 1 , wherein a male thread formed on the fixing portion is screwed into a female thread formed on the support plate and fixed thereto.

3. a center position of the first coil body and a center position of the second coil body when viewed in the normal direction are disposed at the same position in the second direction, The coil unit according to claim 1 , wherein an outer edge portion of the first coil body and an outer edge portion of the second coil body when viewed in the normal direction are disposed at the same position in the second direction.

4. A plurality of the fixing members are provided, The coil unit according to claim 1 , wherein the plurality of fixing members are arranged symmetrically with respect to a virtual line connecting a central position of the first coil body and a central position of the second coil body when viewed in the normal direction.

5. a core made of a magnetic material is disposed between the first coil body, the second coil body and the support plate; the core is continuously disposed in the first direction so as to overlap both a center position of the first coil body and a center position of the second coil body when viewed in the normal direction, The coil unit according to claim 1 , wherein the core is disposed so as to be in contact with the support surface.

6. A method for manufacturing a coil unit including a support plate, a coil, and a molding resin, comprising the steps of: a coil arrangement step of arranging the coil including a first coil body and a second coil body along a support surface of the support plate, a fixing member arrangement step of arranging a fixing member, and a resin supply step of supplying a resin, which is performed after the coil arrangement step and the fixing member arrangement step, In the coil arrangement step, the first coil body and the second coil body are each formed into an annular shape when viewed in a normal direction along the normal direction of the support surface, and the first coil body and the second coil body are arranged so as to be adjacent to each other in a first direction, which is a specific direction along the support surface; A direction perpendicular to the first direction when viewed in the normal direction is defined as a second direction, a curved portion is a portion of each of the first coil body and the second coil body that faces each other in the first direction and is formed so as to move toward a side that moves away from each other in the first direction as it moves toward an outer side in the second direction, In the fixing member arrangement step, the fixing member is arranged between the curved portion of the first coil body and the curved portion of the second coil body in the first direction, a fixing portion of the fixing member is fixed to the support plate, and an extension portion extending from the fixing portion is arranged so as to extend on a side where the first coil body and the second coil body are arranged with respect to the support surface; A method for manufacturing a coil unit, in which the resin supplying process supplies the resin to an area adjacent to the support surface of the support plate so that the first coil body, the second coil body, and the extension portion are embedded in the resin.

Images