Coil unit

• US 10,170,236 B2
• Filed: 10/02/2017
• Issued: 01/01/2019
• Est. Priority Date: 11/17/2016
• Status: Active Grant

• Current Assignee: Toyota Jidosha Kabushiki Kaisha (Toyota Motor Corporation)
• Original Assignee: Toyota Jidosha Kabushiki Kaisha (Toyota Motor Corporation)
• Inventors: Doi, Taiga
• Primary Examiner(s): Chan, Tsz
• Application Number:
  US15/722,674
• Publication Number:
  US 20180137970A1
• Time in Patent Office: 456 Days
• Field of Search: 336200, 336232
• CPC Class Codes: B60L 3/0015 Prevention of collisions
• CPC Class Codes: B60L 53/12 Inductive energy transfer
• CPC Class Codes: H01F 27/02 Casings
• CPC Class Codes: H01F 27/363 made of electrically conductive material
• CPC Class Codes: H01F 38/14 Inductive couplings for wireless supply or distribution of electric power using inductive coupling H02J50/10
• CPC Class Codes: H02J 2310/48 for electric vehicles [EV] or hybrid vehicles [HEV]
• CPC Class Codes: H02J 50/10 using inductive coupling
• CPC Class Codes: H02J 50/12 of the resonant type
• CPC Class Codes: H02J 50/70 involving the reduction of electric, magnetic or electromagnetic leakage fields
• CPC Class Codes: Y02T 10/70 Energy storage systems for electromobility, e.g. batteries
• CPC Class Codes: Y02T 10/7072 Electromobility specific charging systems or methods for batteries, ultracapacitors, supercapacitors or double-layer capacitors
• CPC Class Codes: Y02T 90/12 Electric charging stations
• CPC Class Codes: Y02T 90/14 Plug-in electric vehicles

Abstract

A coil unit includes: a first case; a second case; a ferrite plate; a coil; a shield member; and a seal member. The ferrite plate, the coil and the shield member are arranged inside an accommodation space. The first case includes a first plate portion, a first circumferential wall portion and a first joint face. The second case includes a second plate portion, a second circumferential wall portion, a second joint face, a protruding portion and a through-hole. At least part of a portion at which the first joint face and the second joint face are joined with each other is located closer to the second plate portion than the ferrite plate. An inner periphery of the second case, which defines the through-hole, includes a large-diameter portion and a small-diameter portion respectively provided at both ends. The seal member is arranged inside the large-diameter portion.

Claims

1. A coil unit comprising:

a first case and a second case facing each other in a predetermined direction, the first case and the second case defining an accommodation space inside when joined with each other;

a ferrite plate, a coil and a shield member that are arranged in the accommodation space; and

a seal member attached to the second case for taking a wiring member outside from an inside of the accommodation space, the wiring member being electrically connected to the coil, wherein

the first case includes a first plate portion, a first circumferential wall portion provided so as to be upright from a periphery of the first plate portion, and a first joint face located at a distal end of the first circumferential wall portion in a direction in which the first circumferential wall portion is upright, and the first case is configured such that magnetic fluxes pass through the first case,

the second case includes a second plate portion arranged to face the first plate portion, a second circumferential wall portion provided so as to be upright from a periphery of the second plate portion, and a second joint face located at a distal end of the second circumferential wall portion in a direction in which the second circumferential wall portion is upright, and the second case is configured to block magnetic fluxes,

the first case and the second case define the accommodation space when the first joint face and the second joint face are joined with each other,

the ferrite plate is arranged in the accommodation space such that a thickness direction of the ferrite plate is parallel to the predetermined direction,

the coil is arranged between the first plate portion and the ferrite plate such that a winding axis of the coil is parallel to the predetermined direction,

the shield member is arranged between the second plate portion and the ferrite plate so as to support the ferrite plate,

at least part of a portion at which the first joint face and the second joint face are joined with each other is located closer to the second plate portion than a position of the ferrite plate in a direction parallel to the predetermined direction,

the second case further includes a protruding portion and a through-hole, the protruding portion protrudes outward from a position of the second circumferential wall portion when viewed in the direction parallel to the predetermined direction, the through-hole extends through the protruding portion and the second circumferential wall portion so as to communicate with the accommodation space, the wiring member and the seal member are arranged inside the through-hole,

an inner periphery of the second case, which defines the through-hole, includes a large-diameter portion and a small-diameter portion, the large-diameter portion is provided at an end opposite from a side on which the accommodation space is located and at a position that does not overlap with the second joint face when viewed in the direction parallel to the predetermined direction, the small-diameter portion connects the large-diameter portion with the accommodation space, the small-diameter portion is smaller in inside diameter than the large-diameter portion, and

the seal member is arranged inside the large-diameter portion.

2. The coil unit according to claim 1, wherein

all the portion at which the first joint face and the second joint face are joined with each other is located closer to the second plate portion than the position of the ferrite plate in the direction parallel to the predetermined direction.

3. The coil unit according to claim 1, wherein

the protruding portion includes a first cylindrical portion and a second cylindrical portion, the second cylindrical portion is located on an outer side of the first cylindrical portion when viewed in the predetermined direction, the second cylindrical portion is larger in outside diameter than the first cylindrical portion,

part of an outer periphery of the first cylindrical portion, which is connected with the second joint face, is flush with the second joint face and is located closer to the second plate portion than part of an outer periphery of the second cylindrical portion, which is connected with the part of the outer periphery of the first cylindrical portion, and

the second cylindrical portion has the large-diameter portion inside.

4. The coil unit according to claim 1, wherein

the inner periphery of the second case, which defines the small-diameter portion, has a tapered portion of which a circumference increases from a side of the accommodation space toward an outer side of the second case.