CONTACTLESS POWER TRANSFER APPARATUS

• US 20140084697A1
• Filed: 01/18/2012
• Published: 03/27/2014
• Est. Priority Date: 01/19/2011
• Status: Active Grant

• Current Assignee: Technova, Inc. (Aisin Corp.), National University Corporation Saitama University
• Original Assignee: Technova, Inc. (Aisin Corp.), National University Corporation Saitama University
• Inventors: Yasuda, Tomio, Kishi, Hiroyuki, Abe, Shigeru, Suzuki, Akira
• Granted Patent: US 9,312,729 B2
• Time in Patent Office: Days
• US Class Current: 307/104
• CPC Class Codes: B60L 2210/30 AC to DC converters
• CPC Class Codes: B60L 2210/40 DC to AC converters
• CPC Class Codes: B60L 2240/36 Temperature of vehicle components or parts
• CPC Class Codes: B60L 53/12 Inductive energy transfer
• CPC Class Codes: B60L 53/34 Plug-like or socket-like devices specially adapted for contactless inductive charging of electric vehicles positioning means for charging devices using inductive energy transfer B60L53/38
• CPC Class Codes: B60M 7/003 for vehicles using stored power (e.g. charging stations)
• CPC Class Codes: H01F 2003/106 Magnetic circuits using combinations of different magnetic materials
• CPC Class Codes: H01F 27/02 Casings
• CPC Class Codes: H01F 3/10 Composite arrangements of magnetic circuits
• 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 50/10 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 10/72 Electric energy management in electromobility
• CPC Class Codes: Y02T 90/12 Electric charging stations
• CPC Class Codes: Y02T 90/14 Plug-in electric vehicles

Abstract

A contactless power transfer core used for a power transmission coil or a power reception coil of a contactless power transfer apparatus includes: a winding core part wound by an electric wire; and a magnetic pole core part constituting a magnetic pole portion provided at both sides of the winding core part. A height of the uppermost part of a ferrite plate arranged on a face of the magnetic pole core part at a side opposing a counterpart coil is equal to or greater than a height of an outer circumference of the electric wire wound around the winding core part, and a height of the ferrite plate of a face at a side not opposing the counterpart coil is lower than the height of the outer circumference of the electric wire wound around the winding core.

Claims

1. A contactless power transfer apparatus comprising:

one of a power transmission coil and a power reception coil opposing each other to perform contactless power transfer held in a case, wherein;

the power transmission coil or the power reception coil held in the case includes a core and an electric wire, the core having magnetic pole portions at both ends and a wound portion around which the electric wire is wound between the magnetic pole portions, the electric wire being wound around the wound portion of the core; and

,

the magnetic pole portions of the core are formed from a pair of parallel magnetic members, the wound portion of the core is formed of a magnetic member which is perpendicular to the magnetic pole portions, and the core is formed in H-shape by the pair of magnetic members constituting the magnetic pole portions and the magnetic member constituting the wound portion; and

,

with reference to a position of a wide core surface of the wound portion, at a side opposing a counterpart coil, a height of a face of the magnetic pole portions opposing the counterpart coil of the core is equal to or greater than a height of an outer circumference of the electric wire wound around the wound portion, and at a side not opposing the counterpart coil, a height of a core face is less than the height of the outer circumference of the electric wire wound around the wound portion.

2. The contactless power transfer apparatus of claim 1, wherein a length of a long side of a magnetic pole portion core member is larger than a length of a winding portion in the same direction.

3. The contactless power transfer apparatus of claim 2, wherein the power transmission coil or the power reception coil having the core of H-shape is held in the case formed by a resin, the case is fixed to a non-magnetic conductor plate for magnetic screening, a housing is arranged on an opposite face of a face of the non-magnetic conductor plate to which the case is fixed, and at least a capacitor which is connected to the coil in the case in parallel and a rectifying circuit are held in the housing.

4. The contactless power transfer apparatus of claim 3, wherein the case has a case through hole arranged near a center line which divides a spacing between the parallel magnetic pole portions of the core of H-shape into two parts, the non-magnetic conductor plate has a communicating through hole which overlaps the case through hole, and a lead wire of the electric wire wound around the wound portion of the core is inserted into the case through hole and the communicating through hole to be led into the housing and electrically connected to the capacitor and the rectifying circuit.

5. The contactless power transfer apparatus of claim 4, wherein the case through holes of the case are formed as a pair arranged to interpose the center line therebetween, and a lead wire connected to one end of the electric wire wound around the wound portion of the core and a lead wire connected to other end of the electric wire are inserted into the paired case through holes, respectively.

6. The contactless power transfer apparatus of claim 5, wherein the communicating through holes of the non-magnetic conductor plate which overlap the case through holes and formed as a pair are connected to each other by a slit.

7. The contactless power transfer apparatus of claim 5, wherein a plurality of electric wires are wound around the wound portion of the core in parallel, and a number of pairs of the case through holes arranged to interpose the center line of the case therebetween corresponds to the number of electric wires.

8. The contactless power transfer apparatus of claim 3, wherein an area of the non-magnetic conductor plate is larger than a contact area of the case with respect to the non-magnetic conductor plate, and the case is fixed to the non-magnetic conductor plate so that a center position of the held power transmission coil or the power reception coil matches with a center position of the non-magnetic conductor plate.

9. The contactless power transfer apparatus of claim 1, wherein the case has a space holding the power transmission coil or the power reception coil, the case includes a resin cover in which a face opposite the face facing the counterpart coil is open and a fixing plate fixed to the resin cover so as to close the opening of the resin cover, and the fixing plate is formed of a non-magnetic conductive metal material.

10. The contactless power transfer apparatus of claim 9, wherein a high thermal conductive insulating resin is interposed between the fixing plate and the electric wire wound around the wound portion of the core.

11. The contactless power transfer apparatus of claim 10, wherein the electric wire is wound around the wound portion of the core to form a multiple layers, and a thickness of the high thermal conductive insulating resin is set to a thickness so that at least one layer of the electric wire is buried in the high thermal conductive insulating resin.

12. The contactless power transfer apparatus of claim 10, wherein the high thermal conductive insulating resin is interposed also between the fixing plate and a part of the core other than the wound portion.

13. The contactless power transfer apparatus of claim 9, wherein the wound portion of the core is covered by a winding bobbin formed by the high thermal conductive insulating resin, and the electric wire is wound around the winding bobbin.

14. The contactless power transfer apparatus of claim 9, wherein a cooling insulating oil is enclosed in the case, and a protrusion for enlarging a contact area with respect to the cooling insulating oil is provided on a contact face of the fixing plate with respect to the cooling insulating oil.

15. The contactless power transfer apparatus of claim 14, wherein the protrusion is provided within a range so that eddy-current loss in the fixing plate due to the leakage magnetic flux from the coil does not exceed a predetermined amount.

16. The contactless power transfer apparatus of claim 1, wherein the wound portion of the core is formed of a laminated body in which a plurality of amorphous magnetic alloy ribbons are laminated, the magnetic pole portions of the core are formed by a ferrite, a laminated face of the laminated body is parallel to a surface of the wound portion from one of the magnetic pole portions to other one of the magnetic pole portions, and an end face of the wound portion at which the end faces of the ribbons appear abuts against the magnetic pole portions.

17. The contactless power transfer apparatus of claim 16, wherein the wound portion of the core is formed of the laminated body including a flat panel shape part and a bent part which is bent in a direction of the magnetic pole portions at an end edge side of the flat panel shape part which abuts against the magnetic pole portions.

18. The contactless power transfer apparatus of claim 16, further comprising:

a rectangular coil bobbin comprising an insertion hole into which the wound portion of the core is inserted; and

two magnetic pole cases holding the magnetic pole portions of the core, respectively, wherein

the wound portion is inserted into the insertion hole of the coil bobbin so as to expose the end faces, and the coil bobbin and the magnetic pole cases are coupled so that the end faces of the wound portion exposed from the insertion hole abuts against the magnetic pole portions held in the magnetic pole cases, respectively.

19. The contactless power transfer apparatus of claim 18, wherein the wound portion is formed from two laminated bodies comprising a flat plate shape part and a bent part which is bent in the direction of the magnetic pole portions at one end edge side of the flat plate shape part which abuts against the magnetic pole portions, and each of the laminated bodies is inserted from an opening at both sides communicating to the insertion hole of the coil bobbin so that distal ends of the flat plate shape parts abut against each other in the insertion hole as well as the bent part protrudes from the insertion hole, and end faces of the bent parts abut against the magnetic pole portions in the magnetic pole case, respectively.