Power transmission device, method for manufacturing the same, power reception device and method for manufacturing the same

• US 10,447,086 B2
• Filed: 07/01/2015
• Issued: 10/15/2019
• Est. Priority Date: 08/20/2014
• Status: Active Grant

• Current Assignee: Toyota Jidosha Kabushiki Kaisha (Toyota Motor Corporation)
• Original Assignee: Toyota Jidosha Kabushiki Kaisha (Toyota Motor Corporation)
• Inventors: Yuasa, Hiroaki
• Primary Examiner(s): Barnie, Rexford N
• Assistant Examiner(s): Vu, Toan T
• Application Number:
  US15/503,410
• Publication Number:
  US 20170237295A1
• Time in Patent Office: 1,567 Days
• Field of Search: 307104
• CPC Class Codes: B60L 5/00 Current collectors for power supply lines of electrically-propelled vehicles current collectors in general H01R41/00
• CPC Class Codes: B60L 50/60 using power supplied by batteries in combination with fuel cells B60L50/75
• CPC Class Codes: B60L 53/122 Circuits or methods for driving the primary coil, e.g. supplying electric power to the coil
• CPC Class Codes: B60M 7/00 Power lines or rails specially adapted for electrically-propelled vehicles of special types, e.g. suspension tramway, ropeway, underground railway
• CPC Class Codes: H01F 27/02 Casings
• CPC Class Codes: H01F 27/04 Leading of conductors or axles through casings, e.g. for tap-changing arrangements
• CPC Class Codes: H01F 27/24 Magnetic cores
• CPC Class Codes: H01F 27/2804 Printed windings
• 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 50/12 of the resonant type
• 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 90/14 Plug-in electric vehicles

Abstract

A power transmission device that transmits electric power to a power reception device in a contactless manner includes a power transmission coil unit, an electrical device connected to the power transmission coil unit, and an enclosure storing the power transmission coil unit and the electrical device. The enclosure includes an installation wall, an outer wall, a partitioning wall, and a cover portion closing an opening formed in a power transmission surface of the outer wall and allowing transmission of electric power by the power transmission coil unit. The partitioning wall is provided to partition the space in the enclosure into a coil-unit storing portion in which the cover portion is located and the power transmission coil unit is stored, and an electrical-device storing portion in which the electrical device is stored. The outer wall and the partitioning wall are made of metal.

Claims

1. A power transmission device that transmits electric power to a power reception device in a contactless manner, comprising:

a power transmission coil unit;

an electrical device connected to said power transmission coil unit; and

an enclosure configured to store said power transmission coil unit and said electrical device,

said enclosure including

an installation wall located on the side of an installation surface,

an outer wall provided to cover said installation wall from the side of a side surface and leaving space in said enclosure,

a partitioning wall configured to partition said space, and

a cover portion configured to close an opening formed in a power transmission surface of said outer wall and to allow transmission of electric power by said power transmission coil unit,

said partitioning wall being provided to partition said space in said enclosure into a coil-unit storing portion in which said cover portion is located and said power transmission coil unit is stored, and an electrical-device storing portion in which said electrical device is stored,

said outer wall and said partitioning wall being made of metal,

said outer wall having a main surface wall having said opening formed therein and provided on the side of said power transmission surface, and a sidewall located on the side of said side surface,

said power transmission coil unit including a power transmission coil,

said power transmission coil having a hole formed therein and being arranged such that a winding axis extends through said cover portion and said installation wall,

said electrical device at least including a filter device portion, an AC/DC device portion and a DC/RF device portion, and

at least one of said filter device portion, said AC/DC device portion and said DC/RF device portion being arranged at a position distant from a region located between said hole in said power transmission coil and said installation wall.

2. The power transmission device according to claim 1, wherein said partitioning wall is higher in conductivity than said outer wall.

3. The power transmission device according to claim 1, wherein

said main surface wall and said partitioning wall are formed integrally, and

said installation wall and said sidewall are formed integrally.

4. The power transmission device according to claim 1, wherein said installation wall is made of metal.

5. The power transmission device according to claim 1, wherein said power transmission coil unit includes a flat ferrite plate and a spiral coil arranged on the side of said power transmission surface with respect to said ferrite plate.

6. A method for manufacturing a power transmission device that transmits electric power to a power reception device in a contactless manner,

said power transmission device including

a power transmission coil unit,

an electrical device connected to said power transmission coil unit, and

an enclosure configured to store said power transmission coil unit and said electrical device,

said enclosure including

an installation wall located on the side of an installation surface,

an outer wall provided to cover said installation wall from the side of a side surface and leaving space in said enclosure,

a partitioning wall configured to partition said space and recessed toward said installation surface, and

a cover portion configured to close an opening formed in a power transmission surface of said outer wall and to allow transmission of electric power by said power transmission coil unit,

said partitioning wall being provided to partition said space in said enclosure into a coil-unit storing portion in which said cover portion is located and said power transmission coil unit is stored, and an electrical-device storing portion in which said electrical device is stored,

said outer wall and said partitioning wall being made of metal,

said outer wall having

a main surface wall having said opening formed therein and provided on the side of said power transmission surface, and

a sidewall located on the side of said side surface,

said enclosure including

a main enclosure in which said installation wall and said sidewall are formed integrally, and

a cover member in which said partitioning wall and said main surface wall are formed integrally, and which closes an opening in said main enclosure,

said method comprising the steps of:

storing said electrical device in said main enclosure;

closing, with said cover member, the opening in said main enclosure in which said electrical device is stored;

arranging said power transmission coil unit on an inner side of said partitioning wall of said cover member; and

closing an opening in said partitioning wall with said cover portion.

7. The method for manufacturing a power transmission device according to claim 6, wherein, after arranging said power transmission coil unit in said partitioning wall of said cover member and closing the opening in said partitioning wall with said cover portion, the opening in said main enclosure in which said electrical device is stored is closed with said cover member.

8. A power reception device that receives electric power from a power transmission device in a contactless manner, comprising:

a power reception coil unit;

an electrical device connected to said power reception coil unit; and

an enclosure configured to store said power reception coil unit and said electrical device,

said enclosure including

an installation wall located on the side of an installation surface,

an outer wall provided to cover said installation wall from the side of a side surface and leaving space in said enclosure,

a partitioning wall configured to partition said space, and

a cover portion configured to close an opening formed in a power reception surface of said outer wall and to allow reception of electric power by said power reception coil unit,

said partitioning wall being provided to partition said space in said enclosure into a coil-unit storing portion in which said cover portion is located and said power reception coil unit is stored, and an electrical-device storing portion in which said electrical device is stored,

said outer wall and said partitioning wall being made of metal,

said outer wall having a main surface wall having said opening formed therein and provided on the side of said power reception surface, and a sidewall located on the side of said side surface,

said power reception coil unit including a power reception coil,

said power reception coil having a hole formed therein and being arranged such that a winding axis extends through said cover portion and said installation wall,

said electrical device at least including a capacitor, a rectifier and a DC/DC converter, and

at least one of said rectifier and said DC/DC converter being arranged at a position distant from a region located between said hole in said power reception coil and said installation wall.

9. The power reception device according to claim 8, wherein said partitioning wall is higher in conductivity than said outer wall.

10. The power reception device according to claim 8, wherein

said main surface wall and said partitioning wall are formed integrally, and

said installation wall and said sidewall are formed integrally.

11. The power reception device according to claim 8, wherein said installation wall is made of metal.

12. The power reception device according to claim 8, wherein said power reception coil unit includes a flat ferrite plate and a spiral coil arranged on the side of said power reception surface with respect to said ferrite plate.

13. A method for manufacturing a power reception device that receives electric power from a power transmission device in a contactless manner,

said power reception device including

a power reception coil unit,

an electrical device connected to said power reception coil unit, and

an enclosure configured to store said power reception coil unit and said electrical device,

said enclosure including

an installation wall located on the side of an installation surface,

an outer wall provided to cover said installation wall from the side of a side surface and leaving space in said enclosure,

a partitioning wall configured to partition said space and recessed toward said installation surface, and

a cover portion configured to close an opening formed in a power reception surface of said outer wall and to allow reception of electric power by said power reception coil unit,

said partitioning wall being provided to partition said space in said enclosure into a coil-unit storing portion in which said cover portion is located and said power reception coil unit is stored, and an electrical-device storing portion in which said electrical device is stored,

said outer wall and said partitioning wall being made of metal,

said outer wall having

a main surface wall having said opening formed therein and provided on the side of said power reception surface, and

a sidewall located on the side of said side surface,

said enclosure including

a main enclosure in which said installation wall and said sidewall are formed integrally, and

a cover member in which said partitioning wall and said main surface wall are formed integrally, and which closes an opening in said main enclosure,

said method comprising the steps of:

storing said electrical device in said main enclosure;

closing, with said cover member, the opening in said main enclosure in which said electrical device is stored;

arranging said power reception coil unit on an inner side of said partitioning wall of said cover member; and

closing an opening in said partitioning wall with said cover portion.

14. The method for manufacturing a power reception device according to claim 13, wherein, after arranging said power reception coil unit on the inner side of said partitioning wall of said cover member and closing the opening in said partitioning wall with said cover portion, the opening in said main enclosure in which said electrical device is stored is closed with said cover member.