Coil Unit

Abstract

To provide a coil unit that can secure strength and reduce the board thickness of a case body and a cover member.SOLUTION: A coil unit includes a case body 4 including a housing space that houses a coil formed spirally and a wiring board to which the coil is connected, and a first cover member 5 that covers the housing space. The case body includes a center boss part 47 (first support member) with a cylindrical shape that projects to a side of the first cover member. The first cover member includes a second support member 57 with a cylindrical shape that projects to a side of the case body. In a state where the first cover member is attached to the case body, the first support member and the second support member are disposed in a nest structure and the first support member is in contact with the first cover member to support the first cover member, and the second support member is in contact with the case body to support the case body.SELECTED DRAWING: Figure 21

Description

[Technical field]

[0001] The present invention relates to a coil unit that is disposed on the ground or in an electric vehicle in a non-contact charging system that charges a battery mounted in the electric vehicle. [Background technology]

[0002] In recent years, non-contact charging systems have been attracting attention as a method for charging the on-board batteries of electric vehicles. In a non-contact charging system, power is transmitted between a power transmitting coil unit installed on the ground and a power receiving coil unit installed in the electric vehicle to charge the battery installed in the electric vehicle.

[0003] Coil units used in contactless charging systems need to be strong enough to withstand the risk of vehicles running over them when placed on the ground, and they need to be strong enough to withstand the risk of collisions between the bottom of the vehicle and obstacles, flying stones, etc. On the other hand, in order not to interfere with the magnetic field of the coil, materials that are easy to ensure strength, such as metal, cannot be used for the cover member placed opposite the coil.

[0004] Patent Document 1 discloses a coil unit (power supply coil unit) used in the above-mentioned contactless charging system. This coil unit has a box-shaped case, and a control unit and a coil connected to the control unit are arranged side by side in the space inside the case. The opening of the case is on the side facing the opposing coil unit, and the opening of the case is closed with a resin cover member so as to cover the coil inside the case. [Prior art documents] [Patent documents]

[0005] [Patent Document 1] JP 2014-233107 A Summary of the Invention [Problem to be solved by the invention]

[0006] In the technology described in Patent Document 1, the cover member that covers the coil is made of resin, so it is possible to increase the plate thickness of the case and the cover member to ensure the necessary strength. However, if the plate thickness of the case and the cover member is increased, the case becomes larger, which is an issue in that it is not possible to meet the demand for miniaturization.

[0007] The present invention has been made to solve the above-mentioned problems, and has an object to provide a coil unit that ensures strength while enabling the plate thicknesses of the case body and cover member to be reduced. [Means for solving the problem]

[0008] A coil unit according to a first aspect of the present invention is a coil unit placed on the ground or on an electric vehicle in a contactless charging system that transmits power between a power transmitting side coil unit placed on the ground and a power receiving side coil unit placed on an electric vehicle and charges a battery mounted on the electric vehicle, and comprises a coil formed in a spiral shape, a wiring board to which the coil is connected, a case body having an accommodation space for accommodating the coil and the wiring board, and a cover member attached to the case body and closing the accommodation space, wherein the case body has a cylindrical first support portion protruding toward the cover member, and the cover member has a cylindrical second support portion protruding toward the case body, and when the cover member is attached to the case body, the first support portion and the second support portion are arranged in a nested manner, the first support portion abuts against the cover member to support the cover member, and the second support portion abuts against the case body to support the case body. Effect of the Invention

[0009] According to the coil unit of the present invention, a coil and a wiring board are accommodated in an accommodation space of a case body, and the accommodation space is blocked by a cover member attached to the case body. The case body has a cylindrical first support part protruding toward the cover member side, and the first protruding part abuts against the cover member to support the cover member. The cover member has a cylindrical second support part protruding toward the case body side, and the second protruding part abuts against the case body to support the case body. Here, when the cover member is attached to the case body, the above-mentioned first support part and second support part are arranged in a nested manner, so that the case body and the cover member can be supported by each other at a predetermined part where the strength is reduced in the accommodation space. By supporting the case body and the cover member by each other, efficient reinforcement can be achieved, and the strength of the coil unit can be ensured while the plate thickness of the case body and the cover member can be reduced. [Brief description of the drawings]

[0010] [Figure 1] FIG. 2 is a planar perspective view of the coil unit according to the embodiment; [Diagram 2] FIG. 2 is a bottom perspective view of the coil unit according to the embodiment. [Diagram 3] FIG. 2 is a side view of the coil unit according to the embodiment. [Figure 4] FIG. 2 is an exploded perspective view of the coil unit according to the embodiment. [Diagram 5] FIG. 2 is a planar perspective view of a case body according to the embodiment. [Figure 6] FIG. 2 is a plan view of a case main body according to the embodiment. [Figure 7] FIG. 2 is a bottom perspective view of the case body according to the embodiment. [Figure 8] FIG. 2 is a bottom view of the case body according to the embodiment. [Figure 9] FIG. 4 is a plan perspective view of a first cover member according to the embodiment. [Figure 10] FIG. 4 is a plan view of a first cover member according to the embodiment. [Figure 11]4 is a bottom perspective view of a first cover member according to the embodiment. FIG. [Figure 12] 4 is a plan perspective view of a second cover member according to the embodiment. FIG. [Figure 13] 4 is a bottom perspective view of a second cover member according to the embodiment. FIG. [Figure 14] FIG. 2 is a planar perspective view of the coil case according to the embodiment. [Figure 15] FIG. 2 is a plan view of the coil case according to the embodiment. [Figure 16] FIG. 2 is a bottom perspective view of the coil case according to the embodiment. [Figure 17] FIG. 4 is a bottom view of the coil case according to the embodiment. [Figure 18] 1 is an enlarged perspective view showing a connection structure between a litz wire and a wiring board according to an embodiment of the present invention; [Figure 19] 19 is a cross-sectional view of the terminal member taken along line XIX-XIX in FIG. 18. [Figure 20] 2 is a cross-sectional view of the device case taken along line XX-XX in FIG. 1. [Figure 21] 2 is a cross-sectional view of the device case taken along line XXI-XXI in FIG. 1. [Figure 22] 21 is a cross-sectional view of a device case corresponding to FIG. 20 and showing a modified example of a recess and a protrusion according to the present embodiment. FIG. [Figure 23] 23 is a cross-sectional view of a device case of a modified example of the first support portion and the second support portion according to the present embodiment, corresponding to FIG. 22. [Figure 24] 1 is a schematic diagram of a non-contact charging system according to an embodiment of the present invention. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0011] Hereinafter, a non-contact charging system 100 according to an embodiment of the present invention and a coil unit 1 used in the non-contact charging system 100 will be described with reference to Figs. 1 to 24. In this embodiment, for convenience of explanation, the directions indicated by the up-down, left-right, and front-rear arrows appropriately shown in each figure will be defined as the up-down direction, the left-right direction, and the front-rear direction, respectively. Also, in each figure, some symbols may be omitted to make the drawings easier to see.

[0012] As shown in FIG. 24, the contactless charging system 100 is a system for charging an electric vehicle 200 such as an electric vehicle or a plug-in hybrid vehicle. In the contactless charging system 100, power is transmitted between a power transmission coil unit 1A arranged on the ground and a power reception coil unit 1B arranged in the electric vehicle 200, and a battery 300 mounted on the electric vehicle 200 is charged. The power transmission method is to transmit power by arranging a primary coil 2 accommodated in the power transmission coil unit 1A and a secondary coil 2 accommodated in the power reception coil unit 1B facing each other, and utilizing electromagnetic induction between the coils. Specifically, AC power is supplied from an external power supply device 400 to the power transmission coil unit 1A, causing an induced current to flow in the primary coil 2, generating a magnetic field. The generated magnetic field reaches the secondary coil 2, and the induced current flows in the secondary coil 2, thereby transmitting power.

[0013] Next, a description will be given of the coil units 1A and 1B constituting the above-configured non-contact charging system 100. In the following, when the power receiving side coil unit 1B is not distinguished from the power transmitting side coil unit 1A, they will be simply referred to as coil unit 1.

[0014] 1 to 4, the coil unit 1 includes a box-shaped device case 3 that houses a coil 2 (described later) and the like. The device case 3 includes a case main body 4 in which storage spaces S1, S2 that house the coil 2 and the like are formed, and a first cover member 5 and a second cover member 6 that close openings 41, 42 of the case main body 4.

[0015] As shown in Figs. 5 to 8, the case body 4 has a certain width in the front-rear and left-right directions and is formed in a box shape that is flat in the up-down direction. The case body 4 is made of a non-magnetic material such as aluminum, and is, for example, aluminum die-cast. The case body 4 includes a front wall 4A, a rear wall 4B, a left wall 4C, a right wall 4D, an upper wall 4E, a bottom wall 4F, and a partition wall 4G. The partition wall 4G extends in the front-rear direction so as to connect the middle part of the front wall 4A and the middle part of the rear wall 4B. The upper wall 4E is integrally provided and connected to the upper end of the partition wall 4G, the upper ends of the front wall 4A and the rear wall 4B on the right side of the partition wall 4G, and the upper end of the right wall 4D. The bottom wall 4F is integrally connected to the lower end of the partition wall 4G, the lower ends of the front wall 4A and the rear wall 4B on the left side of the partition wall 4G, and the lower end of the left wall 4C. In the case body 4, the top, bottom, left and right cross sections of the upper wall 4E, the partition wall 4G and the bottom wall 4F are crank-shaped.

[0016] In such a case body 4, a first storage space S1 that opens downward is formed by the top wall 4E, the partition wall 4G, the right wall 4D, the front wall 4A, and the rear wall 4B. In addition, in the case body 4, a second storage space S2 that opens upward is formed by the bottom wall 4F, the partition wall 4G, the left wall 4C, the front wall 4A, and the rear wall 4B. In the case body 4, the partition wall 4G divides the internal space (storage space) of the case body 4 into two, left and right, and the left and right internal spaces open in up-down opposite directions to each other.

[0017] In the case body 4, a first housing space S1 formed on the right side of the partition wall portion 4G houses a coil case 7 that holds the coil 2 and the ferrite core 8 (see FIG. 4). A second housing space S2 formed on the left side of the partition wall portion 4G houses a wiring board 9 to which the coil 2 is connected (see FIG. 4). Although not shown, a resonant circuit section, a control section, and a power conversion section are mainly mounted on the wiring board 9. The resonant circuit section includes a capacitor (resonant capacitor) that is connected in series or parallel to the coil 2. The control section monitors the charging power. The power conversion section includes a rectifier section, and converts the received high-frequency AC power into a predetermined DC power and supplies it to the battery 300 mounted on the electric vehicle 200.

[0018] In the case body 4, the first storage space S1 formed on the right side of the partition wall 4G has a first opening 41 that opens downward. Also, the second storage space S2 formed on the left side of the partition wall 4G has a second opening 42 that opens upward. In the case body 4, the first opening 41 of the first storage space S1 and the second opening 42 of the second storage space S2 are provided separately on opposing side surfaces (4E, 4F) of the case body 4. Therefore, the case body 4 has a crank-shaped structure with a step shape between the first storage space S1 and the second storage space S2 by the partition wall 4G.

[0019] 1 to 23 show the power receiving coil unit 1B mounted on the electric vehicle 200, so the first housing space S1 opens on the lower side facing the counterpart (power transmitting) coil unit 1A installed on the ground. In the power transmitting coil unit 1A, the first housing space S1 opens on the upper side facing the power receiving coil unit 1B.

[0020] As shown in Fig. 7 and Fig. 8, the first storage space S1 is a rectangular box-shaped storage space that opens downward of the device case 3, and the side wall portion is formed by the front wall portion 4A, the rear wall portion 4B, the right wall portion 4D, and the partition wall portion 4G of the case main body 4. These walls 4A, 4B, 4D, and 4G are integrally formed with a plurality of first boss portions 43 for fixing the first cover member 5 to the case main body 4. The plurality of first boss portions 43 protrude from the walls 4A, 4B, 4D, and 4G toward the inside of the first storage space S1, and are formed in a columnar shape with the vertical direction as the axial direction. The outer periphery of the first cover member 5 is fixed to the case main body 4 via the plurality of first boss portions 43.

[0021] As shown in Figs. 9 to 11, the first cover member 5 is a plate-like member made of resin having a predetermined width in the front-rear and left-right directions and a predetermined plate thickness in the up-down direction. The first cover member 5 is disposed on the lower side of the case body 4 (see Fig. 4), and is configured to close the first opening 41 of the first housing space S1 by attaching it to the case body 4. A plurality of first mounting holes 51 penetrating the first cover member 5 in the up-down direction are formed on the outer periphery of the first cover member 5. The plurality of first mounting holes 51 correspond to the plurality of first boss portions 43 provided in the first housing space S1, respectively. The first cover member 5 is attached to the case body 4 by inserting screws 52 (see Figs. 2 and 3) into the first mounting holes 51 and screw holes (female threads) formed in the first boss portions 43.

[0022] As shown in FIG. 11, a cover-side recess 53 is formed on the lower surface 5B of the first cover member 5 at a position corresponding to the first mounting hole 51. The cover-side recess 53 is a cylindrical recess recessed upward, and the first mounting hole 51 is formed on the bottom surface. The screw 52 inserted into the first mounting hole 51 from the outside of the first cover member 5 is inserted into the cover-side recess 53 so as not to protrude from the lower surface 5B of the first cover member 5. Therefore, in the power receiving coil unit 1B mounted on the electric vehicle 200, the lower surface 5B of the first cover member 5 constituting the bottom surface of the electric vehicle 200 can be made flat, so that the aerodynamic performance of the lower part of the vehicle is not deteriorated. In addition, it is possible to suppress contact between the screw 52 and pebbles bouncing off the road surface or obstacles that have entered the lower part of the vehicle during driving.

[0023] In the device case 3, in order to improve the sealing performance of the first storage space S1, a sealant X is applied to the opposing surfaces of the walls 4A, 4B, 4D, and 4G constituting the sidewall portion of the first storage space S1 in the case body 4 and the first cover member 5. As shown in FIG. 7 and FIG. 8, a recess 44 is formed on the lower end surface (the surface to which the sealant X is applied) of the walls 4A, 4B, 4D, and 4G constituting the sidewall portion of the first storage space S1 in the case body 4. The recess 44 is disposed on the inside of the first boss portion 43 in the walls 4A, 4B, 4D, and 4G, and is formed in a line extending around the outer periphery of the first opening 41. As shown in FIG. 20, the recess 44 is formed in a rectangular groove shape that opens toward the first cover member 5 side (lower side), and has a pair of side surfaces 441 disposed opposite to each other and a bottom surface 442 that connects the upper ends of the pair of side surfaces 441.

[0024] 9 and 10, a protrusion 54 is formed on the peripheral portion (portion to which the sealant X is applied) of the upper surface 5A of the first cover member 5. The protrusion 54 is disposed on the inner side of the first mounting hole 51 on the peripheral portion of the upper surface 5A of the first cover member 5, and is configured as a linear protrusion extending all the way around along the peripheral portion of the upper surface 5A. As shown in FIG. 20, the protrusion 54 stands on the upper surface 5A of the first cover member 5 toward the case main body 4 side (upper side), and has a rectangular shape one size smaller than the recess 44 in cross section in a direction perpendicular to the extending direction.

[0025] When attaching the first cover member 5 to the case body 4, the recess 44 of the case body 4 is filled with the sealant X, and then the first cover member 5 is attached to the case body 4 so that the protrusion 54 of the first cover member 5 is inserted into the recess 44 of the case body 4. When the first cover member 5 is attached to the case body 4 in this manner, as shown in FIG. 20, a part of the sealant X in the recess 44 is pressed by the protrusion 54 and pushed out from the recess 44, and the sealant X is interposed between the lower end surfaces of the walls 4A, 4B, 4D, and 4G of the case body 4 and the upper surface 5A of the first cover member 5. A part of the sealant X remains in the recess 44, and the sealant X is interposed between the pair of side surfaces 441 and the bottom surface 442 constituting the recess 44 and each surface constituting the protrusion 54. The sealant X is, for example, a silicone-based wet sealant, which is filled in the recess 44 in a liquid state and becomes an elastic rubber-like material when hardened.

[0026] There are two main reasons for the above-mentioned configuration in which the protrusion 54 of the first cover member 5 is inserted into the recess 44 formed on the case body 4 side. The first reason is to increase the area of ​​the joint between the case body 4 and the first cover member 5, and to increase the joint strength between the case body 4 and the first cover member 5 by the seal material X. This prevents the first housing space S1 from opening even if a part of the first cover member 5 is separated from the case body 4 when the linear expansion and contraction difference between the metal case body 4 and the resin first cover member 5 becomes large. The second reason is that by interposing the elastic seal material X between the recess 44 and the protrusion 54, the linear expansion and contraction difference between the case body 4 and the resin first cover member 5 can be efficiently absorbed in multiple directions by the elastic deformation of the seal material X.

[0027] The second reason will be specifically described. For example, when the vehicle is cooled in a cold region, the resin-made first cover member 5, which has a large linear expansion coefficient, shrinks more than the metal case body 4, so that an external force may act on the first cover member 5 in a direction to separate the first cover member 5 from the first opening 41 of the case body 4. At this time, the seal material X in the vicinity of the side surface 441 of the recess 44 elastically deforms following the side surface of the protrusion 54 of the first cover member 5, so that the linear expansion and contraction difference can be absorbed while maintaining the sealing property between the case body 4 and the first cover member 5. On the other hand, for example, when the vehicle is hot immediately after driving, the resin-made first cover member 5 expands more than the metal case body 4, so that the separation distance t1 between the side surface of the recess 44 and one side surface of the protrusion 54 of the first cover member 5 may become small. Since the sealant X near the side surface 441 of the recess 44 elastically deforms so as to be pushed toward the bottom surface 442 of the recess 44, the difference in linear expansion and contraction can be absorbed while maintaining the sealing performance between the case body 4 and the first cover member 5.

[0028] As shown in FIG. 20, when the first cover member 5 is attached to the case body 4, the distance t2 between the tip of the convex portion 54 and the bottom surface 442 of the concave portion 44 is set to be larger than the distance t1 between the side surface of the convex portion 54 and the side surface of the concave portion 44. This configuration is intended to efficiently absorb the expansion and contraction difference between the case body 4 and the first cover member 5. That is, as described above, it is assumed that the relative positional relationship between the side surface of the convex portion 54 of the first cover member 5 and the side surface 441 of the concave portion 44 changes significantly due to an increase in the linear expansion and contraction difference between the case body 4 and the first cover member 5. If the positional relationship between the side surface of the convex portion 54 and the side surface 441 of the concave portion 44 changes significantly, there is a risk that the expansion and contraction difference cannot be absorbed by the space on both sides of the side surface of the convex portion 54. Therefore, the seal layer on the bottom surface 442 side of the recess 44, which communicates with the spaces on both sides of the side surface of the protrusion 54, is made thicker by increasing the distance t2 between the tip of the protrusion 54 and the bottom surface 442 of the recess 44. By making the seal layer on the bottom surface 442 side of the recess 44 thicker, the seal material X can be efficiently deformed even in a state where the expansion and contraction difference cannot be fully absorbed in the spaces on both sides of the side surface of the protrusion 54, so that the expansion and contraction difference between the case main body 4 and the first cover member 5 can be efficiently absorbed.

[0029] Furthermore, the walls 4A, 4B, 4D, and 4G that form the first housing space S1 in the case body 4 have an inclined surface 45 formed by chamfering the corners on the first housing space S1 side. This configuration is intended to increase the airtightness of the first housing space S1. The inclined surface 45 is inclined so that the gap between the inclined surface 45 and the opposing surface (upper surface 5A) of the first cover member 5 becomes larger as it approaches the inside of the first housing space S1. Therefore, when the liquid sealant X is filled in the recess 44 and the first cover member 5 is attached to the case body 4, the sealant X pushed out from the inside of the recess 44 to the first housing space S1 side by the protrusion 54 remains between the inclined surface 45 and the upper surface 5A of the first cover member 5, forming a thick seal layer. This can increase the airtightness of the first housing space S1. In addition, by retaining the excess portion of the sealant X between the inclined surface 45 and the first cover member 5, the sealant X is prevented from flowing into the first housing space S1.

[0030] As shown in FIG. 7 and FIG. 8, a central boss portion 47 protruding downward is disposed on the lower surface of the upper wall portion 4E of the case body 4 at the center of the first housing space S1. The central boss portion 47 (first support portion) is formed in a cylindrical shape with the vertical direction as the axial direction, and the central portion of the first cover member 5 is fixed to the case body 4 via the central boss portion 47. As shown in FIG. 21, a recessed portion 46 recessed upward is formed in the center of the lower surface of the central boss portion 47. The recessed portion 46 forms the lower end portion of the central boss portion 47 into a cylindrical shape. A female screw hole is formed in the center of the recessed portion 46. When the first cover member 5 is attached to the case body 4, the lower end surface of the central boss portion 47 abuts against the opposing surface (upper surface 5A) of the first cover member 5 to support the first cover member 5 from inside the first housing space S1. An annular recess 471 is formed in the lower end surface (surface facing the first cover member 5) of the central boss portion 47. The recess 471 is formed in a rectangular groove shape that opens toward the first cover member 5 side (downward), and the inside of the recess 471 is filled with a sealant X.

[0031] As shown in Figs. 9 and 10, a cylindrical protrusion 59 is formed on the upper surface 5A of the first cover member 5 at a position facing the central boss portion 47 (the central position of the upper surface 5A). A screw hole 55 penetrating in the vertical direction is formed at the center of the protrusion 59. As shown in Fig. 21, the protrusion 59 of the first cover member 5 is inserted into the recess 46 of the central boss portion 47 of the case body 4, and the screw 52 inserted into the screw hole 55 is screwed into the female screw hole of the recess 46, whereby the first cover member 5 is fixed to the case body 4. A cover-side recess 53 is formed on the lower surface 5B of the first cover member 5 at a position corresponding to the protrusion 59 and the screw hole 55. The cover-side recess 53 has the same configuration as the cover-side recess 53 provided in the first cover member 5 corresponding to the first mounting hole 51, and therefore will not be described. The screw 52 inserted into the screw hole 55 from the outside of the first cover member 5 is inserted into the cover side recess 53 and does not protrude from the lower surface 5B of the first cover member 5.

[0032] As shown in FIG. 9 and FIG. 10, an annular convex portion 56 is integrally formed on the upper surface 5A of the first cover member 5 so as to surround the protrusion 59. As shown in FIG. 21, the convex portion 56 is erected upward from the upper surface 5A of the first cover member 5, and has a rectangular cross section in a direction perpendicular to the extending direction. The first cover member 5 is attached to the case body 4 in a state in which the convex portion 56 is inserted into the recessed portion 471 of the case body 4 (central boss portion 47) filled with the seal material X, and the seal material X is interposed between the upper surface 5A of the first cover member 5 and the lower end surface of the central boss portion 47. When the first cover member 5 is attached to the case body 4 in this manner, a part of the seal material X in the recessed portion 471 is pressed by the convex portion 56 and pushed out from the recessed portion 471, and the seal material X is interposed between the lower end surface of the central boss portion 47 and the upper surface 5A of the first cover member 5. A part of the sealant X remains in the recess 471, and the sealant X is interposed between each surface constituting the recess 471 and each surface constituting the protrusion 56. This makes it possible to ensure airtightness of the first housing space S1 by tightly adhering the case body 4 and the first cover member 5 via the sealant X, and further makes it possible to absorb the difference in linear expansion and contraction between the case body 4 and the first cover member 5.

[0033] As shown in Figs. 9 and 10, a cylindrical second support portion 57 protruding upward is formed on the upper surface 5A of the first cover member 5 at a position radially outside the annular protrusion 56. The second support portion 57 is formed in a double cylindrical shape by an inner wall 571 formed in a cylindrical shape centered on the screw hole 55 and erected upward from the upper surface 5A of the first cover member 5, and a cylindrical outer wall 572 erected radially outside the inner wall 571 and upward from the upper surface 5A. The inner wall 571 and the outer wall 572 are connected by a plurality of ribs 573 to form a lattice shape when viewed from the axial direction. As shown in Fig. 21, when the first cover member 5 is attached to the case body 4, the second support portion 57 is arranged in a nested shape with the central boss portion 47 (first support portion) of the case body 4 inside. At this time, the upper end of the second support portion 57 abuts against the opposing surface of the case body 4 (the lower surface of the upper wall portion 4E), supporting the case body 4 from inside the first housing space S1. The central boss portion 47 and the second support portion 57, which are nested, are disposed within the central space of the coil 2 when the coil 2 is housed in the first housing space S1.

[0034] As described above, the coil 2 is held by the coil case 7 and accommodated in the first accommodation space S1 of the case body 4. As shown in Figs. 14 to 17, the coil case 7 is a resin plate-like member having a predetermined width in the front-rear and left-right directions and a predetermined thickness in the up-down direction, and is formed in a rectangular shape when viewed from the up-down direction. A rectangular opening 71 is formed in the center of the coil case 7, penetrating the coil case 7 in the up-down direction. When the coil case 7 is accommodated in the first accommodation space S1, the central boss portion 47 of the case body 4 and the second support portion 57 of the first cover member 5 are disposed inside the opening 71. The upper surface side of the coil case 7 is a core fixing surface 7A to which a plurality of ferrite cores 8 are fixed. The core fixing surface 7A is partitioned into a grid by a plurality of partition wall portions 72, and a rectangular plate-like ferrite core 8 is fixed to each of the sections.

[0035] A coil insertion hole 73 that penetrates the coil case 7 in the up-down direction is formed on the outside of the opening 71 of the coil case 7. One end 2A (see FIG. 4) of the coil 2 held on the lower surface side of the coil case 7 is inserted into the coil insertion hole 73 and drawn out to the core fixing surface 7A side of the coil case 7. One end 2A of the coil 2 drawn out to the core fixing surface 7A side is inserted and held in a groove-shaped first coil guide portion 74A provided on the left end side of the core fixing surface 7A of the coil case 7.

[0036] The lower surface side of the coil case 7 is a coil fixing surface 7B for fixing the coil 2. The coil fixing surface 7B is formed with a coil accommodating groove 76 formed in a spiral shape. As an example, the coil accommodating groove 76 is a rectangular groove opening downward, and the wire material forming the coil 2 is inserted inside. In this embodiment, the coil 2 is made of a litz wire 21 to prevent an increase in winding resistance due to the skin effect. The litz wire 21 is formed by twisting together a plurality of wire materials (thin wires) that are insulated, and is inserted into the coil accommodating groove 76 of the coil case 7 to form the coil 2 formed in a spiral shape. In this way, the spiral coil 2 is arranged on the coil fixing surface 7B (on the surface) of the coil case 7. The coil 2 has both ends 2A, 2A, and the one end 2A arranged on the central space side of the coil 2 is drawn out to the core fixing surface 7A on the upper surface side through the coil insertion hole 73 described above. On the other hand, the other end 2A of the coil 2, which is arranged radially outward, is inserted into and held in a second coil guide portion 74B that extends from the end of the coil accommodating groove 76 to the left end side of the coil fixing surface 7B.

[0037] A plurality of coil case side bosses 75 are integrally formed on the outer periphery of the coil case 7 and the inner surface of the opening 71. The coil case 7 is fixed to the upper wall 4E of the case body 4 via the plurality of coil case side bosses 75. The upper wall 4E is provided with a case body side boss 48 at a position facing the coil case side boss 75 of the coil case 7 (see FIG. 8). The coil case 7 is fixed in the first housing space S1 of the case body 4 by inserting a screw (not shown) through the coil case side boss 75 and the case body side boss 48.

[0038] As shown in Fig. 8, in the coil case 7 fixed in the first housing space S1 of the case body 4, both ends 2A, 2A of the coil 2 held by the first coil guide portion 74A and the second coil guide portion 74B extend toward the partition wall portion 4G constituting the left wall portion of the first housing space S1, and are guided into the second housing space S2 through an insertion hole 49 formed in the partition wall portion 4G. Both ends 2A, 2A of the coil 2 guided into the second housing space S2 are connected to a mounting surface 9A on the upper surface of a wiring board 9 accommodated in the second housing space S2 via terminal members 22 (see Fig. 18). The detailed configuration of the terminal members 22 will be described later.

[0039] The insertion hole 49 is formed across the partition wall 4G and the bottom wall 4F of the case body 4, and penetrates the partition wall 4G in the left-right direction to connect the first storage space S1 and the second storage space S2, and penetrates the bottom wall 4F in the up-down direction to connect the second storage space S2 and the outside. The insertion hole 49 is disposed on the inside of the recess 44 extending along the first opening 41 of the case body 4. Therefore, when the first cover member 5 is attached to the case body 4, the periphery of the insertion hole 49 is sealed with the sealant X, so that water droplets and the like are prevented from entering the inside of the device case 3 from the outside through the insertion hole 49.

[0040] As described above, the case body 4 is die-cast, and the insertion hole 49 has a portion that opens in the vertical direction, so it can be formed by a die-casting mold consisting of only upper and lower molds. Therefore, a mold that requires lateral insertion and removal is not required, and the mold can be easily constructed. When the first cover member 5 is attached to the case body 4, the lower side of the insertion hole 49 is blocked by a protruding portion 58 protruding from the left end portion 5L of the first cover member 5 (see Figures 10 and 2). A step portion 4H formed along the shape of the left end portion 5L of the first cover member 5 is formed on the surface of the bottom wall portion 4F, and when the left end portion 5L of the first cover member 5 is overlapped on the lower surface side of the partition wall portion 4G, the first cover member 5 is positioned by being fitted into the step portion 4H of the bottom wall portion 4F, and the lower surface of the bottom wall portion 4F and the lower surface 5B of the first cover member 5 are flush with each other.

[0041] 18 and 19, a connection structure between the litz wire 21 and the wiring board 9 at both ends 2A, 2A of the coil 2 will be described. In this embodiment, the ends of the litz wire 21 are connected to the wiring board 9 via terminal members 22.

[0042] Conventionally, a method for fixing an end of a litz wire to a wiring board has been known in which the end of the litz wire is crimped to one end of a terminal member that is screwed to the wiring board by fusing (crimping). In a litz wire formed by twisting together multiple wires, the crimped portion between each wire and the terminal member 22 becomes unstable, which causes a problem of power loss due to contact resistance. In addition, the contact resistance between the terminal member, wiring board, and fixing screw is also significant, which also causes power loss.

[0043] As shown in FIG. 18, the terminal member 22 is made of a metal plate-like member, and includes a board fixing portion 23 fixed to the wiring board 9, and a clamping portion 24 formed integrally with the board fixing portion 23 and clamping an end of the litz wire 21. The board fixing portion 23 is made of a long plate-like member having a predetermined plate thickness in the vertical direction, and its lower surface side is placed on the mounting surface 9A on the upper surface of the wiring board 9. The end of the litz wire 21 is placed on the upper surface side of the board fixing portion 23 with the longitudinal direction of the board fixing portion 23 being the extension direction of the litz wire 21. The board fixing portion 23 has a pair of legs 231 formed on one end and the other end in the longitudinal direction, each of which extends toward the wiring board 9. The pair of legs 231 are inserted into through holes 91 that penetrate the wiring board 9 in the vertical direction, and are soldered to be mounted on the wiring board 9.

[0044] The clamping portion 24 has a pair of arms 241 integrally formed on both sides of the substrate fixing portion 23 in the short direction. The pair of arms 241 extend from the substrate fixing portion 23 to the opposite side (upward side) of the leg portion 231, and are disposed on both sides of the litz wire 21 placed on the substrate fixing portion 23. The pair of arms 241 have base end sides protruding from the substrate fixing portion 23 that extend along the circumferential direction of the litz wire 21, and the tip end parts are bent in directions away from each other to form an introduction portion 241A that is tapered and spreads out. The end of the litz wire 21 is attached to the terminal member 22 in a state where it is immersed in molten solder Y in a pre-soldering process to allow the solder Y to soak between the wires (see FIG. 19). At this time, the end of the litz wire 21 is inserted between the introduction portion 241A, and the pair of arms 241 are elastically deformed so as to spread the introduction portion 241A, and inserted inside the pair of arms 241. When the litz wire 21 passes through the introduction portion 241A, the pair of arms 241 that have been spread are restored to their original positions and clamp the end of the litz wire 21. In this embodiment, the pair of clamping portions 24 is provided at two locations along the longitudinal direction of the board fixing portion 23, but the number of pairs of arms 241 can be changed as appropriate, and may be one or three or more. In the terminal member 22, the end of the litz wire 21 covered with solder Y in the preliminary soldering process is clamped between the pair of arms 241, and the solder Y is applied so as to cover the end of the litz wire 21 and the pair of arms 241 (clamping portions 24), thereby connecting the end of the litz wire 21 to the wiring board 9.

[0045] The first notable feature of the above configuration is that the contact portion between the terminal member 22 and the litz wire 21 is stabilized by clamping the end of the litz wire 21 soaked in the solder Y between the pair of arm portions 241 (clamping portions 24) of the terminal member 22. Since each wire constituting the litz wire 21 is clamped between the pair of arm portions 241 while covered with solder Y in the pre-soldering process, each wire of the litz wire 21 does not directly contact the pair of arm portions 241, but is clamped with the solder Y from the pre-soldering process interposed between the pair of arm portions 241. This reduces the contact resistance between the litz wire 21 and the terminal member 22, thereby reducing power loss.

[0046] Secondly, by attaching the solder Y so as to cover the end of the litz wire 21 and the clamped portion 24, the solder Y can be reliably interposed between the litz wire 21 and the terminal member 22. This makes it possible to realize a connection state similar to that achieved when the end of the litz wire 21 (each wire) is directly soldered to the wiring board 9, thereby improving the mechanical joint strength between the litz wire 21 and the terminal member 22 and further stabilizing the contact between the litz wire 21 and the terminal member 22 (wiring board 9) to reduce the contact resistance. In addition, because the litz wire 21 is clamped by the terminal member 22, stress on the solder caused by vibrations and shocks of the vehicle can be reduced.

[0047] The second housing space S2 of the case body 4 will be described below with reference to Figs. 5 and 6. The second housing space S2 is a rectangular box-shaped housing space that opens upward of the case body 4, and side walls are formed by the front wall 4A, rear wall 4B, left wall 4C, and partition wall 4G of the case body 4. A plurality of second bosses 50 for fixing the second cover member 6 to the case body 4 are integrally formed on these walls 4A, 4B, 4C, and 4G. The second housing space S2 accommodates a wiring board 9 and a resonant choke (not shown) for optimizing transmission efficiency. Two connector mounting parts 501 and 502 are formed on the left wall 4C that constitutes the left wall of the second housing space S2. The connector mounting parts 501 and 502 are formed in a cylindrical shape that protrudes from the left wall 4C to the outside of the case body 4, and the housing 11A of the input connector 11 and the housing 12A of the output connector 12 are mounted inside (see Fig. 1). The housings 11A, 12A are each provided with a connection terminal (not shown), which is connected to the mounting surface 9A of the wiring board 9. The input side connector 11 is connected to a cable connector that is electrically connected to a power source (not shown), etc. The output side connector 12 is connected to a cable connector that is electrically connected to the battery 300 of the electric vehicle 200, and supplies the power received by the coil 2 to the battery 300 of the electric vehicle 200.

[0048] As shown in Figs. 12 and 13, the second cover member 6 is a metal plate-like member having a predetermined width in the front-rear and left-right directions and a predetermined plate thickness in the up-down direction. The second cover member 6 is disposed on the upper side of the case body 4, and is configured to close the second opening 42 of the second accommodation space S2 by attaching it to the case body 4. A plurality of second mounting holes 61 penetrating the second cover member 6 in the up-down direction are formed on the outer periphery of the second cover member 6. The plurality of second mounting holes 61 correspond to a plurality of second boss portions 50 provided on each wall portion forming the second accommodation space S2. The second cover member 6 is attached to the case body 4 by inserting screws 62 into the second mounting holes 61 and the second boss portions 50.

[0049] An accommodating recess 63 is formed on the lower surface of the second cover member 6 by pressing the upper surface of the second cover member 6 to protrude upward. The accommodating recess 63 is a rectangular box-shaped accommodating space that opens downward, and accommodates various circuit elements such as capacitors mounted on the wiring board 9, resonant chokes that optimize transmission efficiency, and the like.

[0050] A notable feature of the second housing space S2 is the fixed position of the right end 6R side of the second cover member 6. As described above, in the case body 4, the partition wall 4G that partitions the first housing space S1 and the second housing space S2 is integrally formed with the first boss 43 for attaching the first cover member 5 to the case body 4 and the second boss 50 for attaching the second cover member 6 to the case body 4. Therefore, as shown in Fig. 3, the right end 6R side (position end side) of the second cover member 6 is disposed so as to cover the upper surface side of the partition wall 4G, and the left end 5L side of the first cover member 5 and the right end 6R side of the second cover member 6 are attached to the case body 4 in a state where they are overlapped vertically with the partition wall 4G in between.

[0051] (Action and Effects) As described above, in the coil unit 1 of this embodiment, the coil 2 and the wiring board 9 connected to the coil 2 are accommodated inside the device case 3. The case body 4 of this device case 3 has a first accommodation space S1 and a second accommodation space S2 partitioned by a partition wall portion 4G, and the coil 2 is accommodated in the first accommodation space S1 and the wiring board 9 is accommodated in the second accommodation space S2. In the case body 4, the first accommodation space S1 opens in a direction facing the opposing coil unit, and the second accommodation space S2 opens on the opposite side to the first accommodation space. Therefore, the case body 4 is formed in a crank shape having a step shape between the first accommodation space S1 and the second accommodation space S2 by the partition wall portion 4G, and the rigidity of the cross section is increased, thereby improving the strength of the case body 4. Furthermore, the first opening 41 of the first accommodation space S1 in which the coil 2 is accommodated becomes smaller, and the first cover member 5 can be made smaller, which also increases the strength of the entire device case 3. In this way, the coil unit 1 according to the present invention can improve the strength of the device case 3.

[0052] In this embodiment, a first boss portion 43 for fixing the first cover member 5 and a second boss portion 50 for fixing the second cover member 6 are integrally provided on both side surfaces of the partition wall portion 4G. As a result, as shown in Fig. 3, the left end portion 5L side (one end side) of the first cover member 5 and the right end portion 6R side (one end side) of the second cover member 6 are attached to the case body in an overlapping state with the partition wall portion 4G in between. Therefore, the case body 4 can be made smaller in size compared to a configuration in which the first cover member 5 and the second cover member 6 are fixed side by side on the same surface of the case body 4.

[0053] In addition, since the first boss portion 43 and the second boss portion 50 are integrally provided on both side surfaces of the partition wall portion 4G, the rigidity of the partition wall portion 4G can be increased. Therefore, the rigidity of the crank-shaped portion of the case body 4 can be effectively increased, and the strength of the case body 4 can be further improved.

[0054] Furthermore, according to this embodiment, the partition wall portion 4G has an insertion hole 49 through which the coil 2 is inserted, so that the end portion 2A of the coil 2 can be routed inside the device case 3 and connected to the wiring board 9. Therefore, since no insertion hole communicating with the outside is formed in the device case 3, the waterproof performance inside the device case 3 can be improved.

[0055] Moreover, in this embodiment, the coil 2 is accommodated in a coil accommodating groove 76 formed in the coil fixing surface 7B (surface) of the coil case 7, and is arranged in a spiral shape on the surface of the coil case 7. Therefore, the coil 2 is held in the coil case 7 and can be prevented from swinging during use, so that the coil can be protected from vibrations while the electric vehicle 200 is running. Furthermore, because the coil 2 is arranged on the surface of the coil case 7, the coil case can be made thinner, and therefore the coil unit 1 can be made thinner and lighter.

[0056] In this embodiment, the case body 4 has a recess 44 formed on the surface facing the first cover member 5 in the wall portion (front wall portion 4A, rear wall portion 4B, right wall portion 4D, partition wall portion 4G) that forms the first housing space S1, and the seal material X is filled in the recess 44. The first cover member 5 has a protrusion 54 formed on the surface facing the walls 4A, 4B, 4D, and 4G of the first housing space S1, and the protrusion 54 is inserted into the recess 44 and is attached to the case body 4 with the seal material X interposed between the walls 4A, 4B, 4D, and 4G. When the linear expansion and contraction difference between the case body 4 and the first cover member 5 increases due to the installation environment of the coil unit 1, the seal material X interposed between the recess 44 and the protrusion 54 is deformed. Therefore, the linear expansion and contraction difference can be efficiently absorbed on multiple surfaces, and the opening of the first housing space S1 can be prevented.

[0057] In this embodiment, the walls 4A, 4B, 4D, and 4G of the case body 4 are formed with inclined surfaces 45 formed by chamfering the corners on the first housing space S1 side, and the sealing material X pushed out toward the first housing space S1 side is retained by the inclined surfaces 45. Therefore, a thick sealing layer is formed on the inclined surfaces 45, and the airtightness of the first housing space S1 is improved, so that the waterproof performance of the device case 3 can be improved. In addition, since the excess sealing material X is retained on the inclined surfaces 45 to prevent it from flowing into the first housing space S1, the components such as the coil 2 accommodated in the first housing space S1 can be protected from the sealing material X.

[0058] It is also possible to form a thick portion of the sealing material X between the case body 4 and the first cover member 5 by forming a step portion at the corner portion of the wall portions 4A, 4B, 4D, 4G on the first storage space S1 side, but by forming the corner portion into an inclined surface shape, the sealing material X can be smoothly extruded.

[0059] Furthermore, in this embodiment, in a state in which the first cover member 5 is attached to the case body 4, as shown in FIG. 20, the separation distance t2 between the tip of the convex portion 54 of the first cover member 5 and the bottom surface 442 of the concave portion 44 of the case body 4 is set to be larger than the separation distance t1 between the side surface of the convex portion 54 and the side surface 441 of the concave portion 44. That is, the thickness of the seal layer (sealing material) formed between the tip of the convex portion 54 and the bottom surface 442 of the concave portion is set to be larger than the thickness of the seal layer formed on both sides of the convex portion 54. Since the space on the bottom surface 442 side of the concave portion 44 communicates with the spaces on both sides of the convex portion 54, by making the seal layer of the space on the bottom surface 442 side thicker, deformation of the spaces on both sides of the convex portion 54 due to the linear expansion and contraction difference between the members can be efficiently absorbed.

[0060] In this embodiment, the central boss portion 47 (first support portion) formed on the case body 4 is brought into contact with the first cover member 5, and the second support portion 57 formed on the first cover member 5 is brought into contact with the case body 4, so that the case body 4 and the first cover member 5 support each other. In addition, when the first cover member 5 is attached to the case body 4, the central boss portion 47 and the second support portion 57 are arranged in a nested manner. Therefore, the case body 4 and the first cover member 5 support each other at a predetermined portion in the first housing space S1 where the strength is reduced, and thus the case body 4 and the first cover member 5 can be efficiently reinforced. As a result, the plate thickness of the case body 4 and the first cover member 5 can be reduced.

[0061] Moreover, in this embodiment, the central boss portion 47 and the second support portion 57 are disposed within the central space of the coil 2 housed in the first housing space S1 of the case body 4. Therefore, in the first housing space S1 in which the coil 2 is housed, the central space of the coil 2, which has reduced strength, can be efficiently reinforced.

[0062] In addition, in this embodiment, when the first cover member 5 is attached to the case body 4, the central boss portion 47 of the case body 4 is nested inside the second support portion 57. That is, the second support portion 57 of the first cover member 5 has an inner diameter that can accommodate the central boss portion 47 of the case body 4 inside, so that the opposing surface of the case body 4 can be supported over a wider range. Therefore, even if the case body 4 is made of a material that is relatively easy to form, such as aluminum, as in this embodiment, the strength of the case body 4 can be increased over a wide range, so that both ensuring strength and reducing weight can be achieved. In addition, even if the case body 4 is die-cast, the strength weakness of die-casting can be compensated for by the structure, so that the necessary strength can be ensured and dimensional accuracy and productivity can be improved.

[0063] In addition, in this embodiment, the second support portion 57 has a double cylindrical shape having an inner wall 571 and an outer wall 572, and has a plurality of ribs 573 between the inner wall 571 and the outer wall 572. Therefore, the support area of ​​the case body 4 by the second support portion 57 can be increased, and the case body 4 can be reinforced more effectively. It is also possible to increase the support area for the case body 4 by making the second support portion 57 a single-layer cylindrical shape and increasing the plate thickness. However, when this configuration is applied to the first cover member 5 made of resin as in this embodiment, in addition to the weight of the first cover member 5 increasing, resin sink is likely to occur due to the increase in plate thickness. In this embodiment, the second support portion 57 has a structure in which a plurality of ribs are formed on the inside of the double cylindrical shape, so that the increase in weight of the first cover member 5 can be suppressed and the occurrence of resin sink can be prevented.

[0064] 21, in this embodiment, a screw hole 55 is formed in the center of the second support part 57, and the first cover member 5 is fixed to the case body 4 by inserting a screw 52 through the screw hole 55. Therefore, the central boss part 47 and the central part of the second support part 57 can be reinforced by fixing them with the screw 52. Furthermore, in the second support part 57, an annular protrusion 56 formed so as to surround the screw hole 55 is inserted into the opposing annular recess 471 of the case body 4 via the seal material X, so that the waterproof performance around the screw hole 55 can be ensured. Therefore, a coil unit 1 having sufficient strength and excellent waterproof performance can be obtained.

[0065] In addition, in this embodiment, in order to connect the litz wire 21 constituting the coil 2 to the wiring board 9, the end of the litz wire 21, which is immersed in the melted solder Y in the pre-soldering process and impregnated with the solder Y, is sandwiched by the terminal member 22 fixed to the wiring board 9. Therefore, the solder Y is interposed between the litz wire 21 and the terminal member 22. As a result, compared to a configuration in which the litz wire 21 and the terminal member 22 are directly contacted and crimped by riveting, the contact portion between the litz wire 21 and the terminal member 22 is stabilized, and the contact resistance can be reduced. Furthermore, by attaching the solder Y so as to cover the sandwiched portion 24 of the litz wire 21 and the terminal member 22, the mechanical fixing strength between the litz wire 21 and the terminal member 22 can be easily ensured without increasing the contact resistance. In addition, since the litz wire 21 is sandwiched by the terminal member 22, the stress on the solder caused by the vibration and impact of the car can be reduced.

[0066] In this embodiment, the clamping portion 24 of the terminal member 22 clamps the litz wire 21 with a pair of elastically deformable arms 241, so that the clamping portion 24 can clamp a plurality of types of litz wires 21 with different diameters. Therefore, a plurality of types of litz wires 21 with different diameters can be connected to the wiring board 9 by the common terminal member 22, so that the members can be standardized and a connection structure with excellent versatility can be provided.

[0067] Below, various modified examples that can be applied to the above embodiment will be explained. Note that the same components as those in the above embodiment will be given the same reference numbers and the explanation thereof will be omitted.

[0068] In the above embodiment, the recesses 44 are formed in the walls 4A, 4B, 4D, 4G of the case body 4, and the protrusions 54 are formed in the first cover member 5 on the opposing surfaces of the walls 4A, 4B, 4D, 4G forming the side wall of the first housing space S1 and the first cover member 5. However, the present invention is not limited to this. For example, as shown in a modified example in FIG. 22(A), the protrusions 500 may be formed in the walls 4A, 4B, 4D, 4G of the case body 4, and inserted into the recesses 503 formed in the opposing surfaces of the first cover member 5. In addition, in the above embodiment, the shape of the recesses 44 formed in the case body 4 is a rectangular groove shape, but the present invention is not limited to this. For example, as shown in FIG. 22(B), a protrusion 602 having a hemispherical cross section may be inserted into a groove-shaped recess 600 having a hemispherical cross section. Or, as shown in a modified example in FIG. 22(C), a trapezoidal protrusion 702 may be inserted into a groove-shaped recess 700 having a trapezoidal cross section. Also, a triangular convex portion may be inserted into a groove-shaped concave portion having a triangular cross section.

[0069] In the above embodiment, the central boss portion 47 (first support portion) and the second support portion 57 are configured such that the central boss portion 47 protruding from the case body 4 side is inserted inside the second support portion 57 and arranged in a nested manner, but the present invention is not limited to this. As in the modified example shown in FIG. 23, the second support portion 900 protruding from the first cover member 5 may be inserted inside the central boss portion 800 (first support portion) and arranged in a nested manner. The central boss portion 800 (first support portion) according to the modified example shown in this figure is formed in a cylindrical shape protruding from the upper wall portion 4E of the case body 4 to the first cover member 5 side. A cylindrical protrusion protruding downward is formed in the center of the central boss portion 800, and a female screw hole is formed in the center of the protrusion. In the central boss portion 800, a rectangular groove-shaped annular recess 802 is formed on the surface facing the first cover member 5, and an annular protrusion 902 protruding from the first cover member 5 is inserted inside the recess 802 with a seal material X interposed therebetween. On the other hand, the second support part 900 according to the modified example is disposed inside an annular protrusion 902 formed so as to surround the screw hole 55 formed in the center of the first cover member 5, and is formed in a cylindrical shape protruding from the first cover member 5 to the case body 4 side. The second support part 900 has a double cylindrical shape with an inner wall 904 formed so as to surround the periphery of the screw hole 55 and an outer wall 906 arranged coaxially on the radial outside of the inner wall 904, and has a plurality of ribs 908 between the inner wall 904 and the outer wall 906. When the first cover member 5 is attached to the case body 4, the second support part 900 is disposed in a nested manner inside the first support part 800, and the second support part 57 abuts against the case body 4 to support the case body 4.

[0070] Furthermore, in the above embodiment and each modified example, the coil unit of the non-contact charging system using the magnetic field resonance method has been described, but the coil unit of the present invention is not limited to this, and may be applied to a non-contact charging system using the electromagnetic induction method. [Explanation of symbols]

[0071] 1 coil unit (1A, 1B) 2 Coil 4 Case body 5 First cover member (cover member) 9. Wiring Board 47 Central boss part (first support part) 55 screw hole 56 Convex 57 Second support part 100 Non-contact power supply system 200 Electric Vehicles 300 Battery 471 Recess 571 Inner wall 572 Outside wall 573 Rib S1 First storage space (storage space) X Sealing material

Claims

1. A coil unit that is disposed on the ground or on an electric vehicle in a non-contact charging system that transmits electric power between a power transmission side coil unit disposed on the ground and a power receiving side coil unit disposed on an electric vehicle and charges a battery mounted on the electric vehicle, the coil unit comprising: A coil formed in a spiral shape; a wiring board to which the coil is connected; a case body having an accommodation space for accommodating the coil and the wiring board; a cover member attached to the case body and closing the storage space, The case body has a cylindrical first support portion protruding toward the cover member, The cover member has a cylindrical second support portion protruding toward the case body, When the cover member is attached to the case body, the first support portion and the second support portion are arranged in a nested manner, and the first support portion abuts against the cover member to support the cover member, and the second support portion abuts against the case body to support the case body.

2. The coil unit according to claim 1 , wherein the first support portion and the second support portion are disposed within a central space of the coil housed in the housing space of the case body.

3. The coil unit according to claim 1 or 2, wherein the first support portion is nested inside the second support portion when the cover member is attached to the case body.

4. The coil unit according to claim 3 , wherein the second support portion has a double cylindrical shape having an inner wall and an outer wall, and has a plurality of ribs between the inner wall and the outer wall.

5. the cover member has a screw hole formed in a center portion of the second support portion, and is fixed to the case body by a screw inserted into the screw hole; the cover member has an annular protrusion formed on the inner side of the second support portion so as to surround the screw hole, the case body has an annular recess formed on a surface of the first support portion facing the cover member, The coil unit according to claim 3 or 4, wherein the cover member is attached to the case body by inserting the convex portion into the concave portion filled with a sealing material, and by interposing the sealing material between the cover member and the first support portion.

Images