Method for manufacturing wireless power-transmitting device, and resonator

• US 10,686,333 B2
• Filed: 01/28/2016
• Issued: 06/16/2020
• Est. Priority Date: 08/08/2013
• Status: Active Grant

• Current Assignee: IHI Corporation
• Original Assignee: IHI Corporation
• Inventors: Maekawa, Yuji, Hara, Masakazu
• Primary Examiner(s): Barnie, Rexford N
• Assistant Examiner(s): Inge, Joseph N
• Application Number:
  US15/008,536
• Publication Number:
  US 20160141099A1
• Time in Patent Office: 1,601 Days
• Field of Search: 307104
• CPC Class Codes: H01F 29/08 with core, coil, winding, or shield movable to offset variation of voltage or phase shift, e.g. induction regulators
• 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: H02J 50/70 involving the reduction of electric, magnetic or electromagnetic leakage fields
• CPC Class Codes: H02J 50/90 involving detection or optimisation of position, e.g. alignment

Abstract

Provided is a method for manufacturing a wireless power-transmitting device including a power-transmitter having a transmission coil, and a power-receiver having a reception coil. The method includes forming, in the electrically-conductive member, an eddy current interruption unit configured to change a state of an eddy current, formed in the electrically-conductive member by the transmission coil (reception coil), by interrupting and redirecting a portion of the eddy current to obtain processed electrically-conductive members, and preparing a plurality of types of the processed electrically-conductive members whose eddy current interruption units are different in form from each other; and selecting one type of the processed electrically-conductive member from the plurality of types of the processed electrically-conductive members and arranging the selected one type of the processed electrically-conductive member near the transmission coil (reception coil), thereby finely adjusting the inductance of the transmission coil (reception coil) to reach a preset inductance.

Claims

1. A resonator on a power-transmitting side or a power-receiving side of a wireless power-transmitting system comprising:

a core member formed of a magnetic material and provided with an adjustment hole for adjustment of a resonance frequency of the resonator on the power-transmitting side or the power-receiving side of the wireless power-transmitting system;

a transmission or reception coil wound around the core member; and

an adjusting jig formed of a magnetic material and a non-magnetic material and configured to be inserted into the adjustment hole to adjust the resonance frequency, wherein

the adjustment hole is formed so as to pass through the core member in an axial direction of the transmission or reception coil from one end of the core to another end of the core,

the adjustment jig, when inserted, extends in the axial direction into the adjustment hole from one end of the core to the other end of the core,

the core member is provided with a plurality of the adjustment holes,

the resonator comprises one or more of the adjusting jigs and a number of the one or more adjusting jigs inserted into the adjustment holes depends on an amount of adjustment of the resonance frequency, and

axial directions of the plurality of the adjustment holes are parallel with an axial direction of the transmission coil or an axial direction of the reception coil, and the plurality of the adjustment holes are spaced from each other.

2. The resonator according to claim 1,

wherein the core member is provided with a plurality of the adjustment holes having different depths, and

the adjusting jig is inserted into the adjustment hole having a depth suitable for receiving a length of the adjusting jig.

3. The resonator according to claim 1,

wherein the adjusting jig includes a plate-shaped magnetic body and a plate-shaped non-magnetic body that is laminated on the magnetic body such that a thickness of the adjusting jig is suitable for a size of the adjustment hole, and

wherein the adjusting jig is inserted into the adjustment hole.

4. The resonator according to claim 1,

wherein the adjusting jig is a mixture of a magnetic material and a non-magnetic material, and

the adjusting jig whose ratio of the magnetic material to the non-magnetic material is set at a value suitable for the adjustment of the resonance frequency is inserted into the adjustment hole.

5. The resonator according to claim 1, further comprising:

a lid member configured to prevent slip-out of the adjusting jig inserted into the adjustment hole.

6. The resonator according to claim 1, further comprising:

a capacitor that is connected to the transmission or reception coil and forms a resonance circuit together with the transmission or reception coil.

7. The resonator according to claim 1,

wherein a plurality of the adjusting jigs are provided,

thicknesses of a plurality of the magnetic materials of the plurality of the adjusting jigs are different from each other, and

one of the plurality of the adjusting jigs is configured to be inserted into the adjustment hole such that the resonance frequency is adjusted.

8. A resonator on a power-transmitting side or a power-receiving side of a wireless power-transmitting system comprising:

a core member formed of a magnetic material and provided with a plurality of adjustment holes, having different depths, to adjust a resonance frequency of the resonator on the power-transmitting side or the power-receiving side of the wireless power-transmitting system;

a transmission or reception coil wound around the core member; and

a plurality of adjusting jigs having different lengths and each formed of a magnetic material and a non-magnetic material and configured to be inserted into the plurality of adjustment holes to adjust the resonance frequency, wherein

axial directions of the plurality of adjustment holes are parallel with an axial direction of the transmission coil or an axial direction of the reception coil, and the plurality of adjustment holes are spaced from each other,

each adjustment jig is configured to be inserted into one of the adjustment holes having a depth configured to receive a length of one of the adjustment jigs,

at least one of the plurality of the adjustment holes is formed so as to pass through the core member in the axial direction of the transmission or reception coil from one end of the core to another end of the core, and

the adjustment jig, when inserted, extends in the axial direction into the adjustment hole from the one end of the core to the other end of the core.

9. The resonator according to claim 8,

wherein the adjusting jig includes a plate-shaped magnetic body and a plate-shaped non-magnetic body that is laminated on the magnetic body to set the thickness of the adjusting jig to a thickness suitable for a size of the plurality of the adjustment holes, and

wherein each adjusting jig, having the magnetic body with a thickness suitable for the adjustment of the resonance frequency, is configured to be inserted into one of the plurality of adjustment holes.

10. The resonator according to claim 8,

wherein the adjusting jig, whose ratio of the magnetic material to the non-magnetic material is set at a value suitable for the adjustment of the resonance frequency, is configured to be inserted into the plurality of the adjustment holes.

11. The resonator according to claim 8, further comprising:

a lid member configured to prevent slip-out of the adjusting jig inserted into the plurality of the adjustment holes.

12. The resonator according to claim 8, further comprising:

a capacitor that is connected to the transmission or reception coil and forms a resonance circuit together with the transmission or reception coil.