Coil module and coil unit

Patent metadata

Field	Value
Publication number	US-10978909-B2
Application number	US-201916402420-A
Country	US
Kind code	B2
Filing date	May 3, 2019
Priority date	May 29, 2018
Publication date	Apr 13, 2021
Grant date	Apr 13, 2021

Abstract

A coil module includes: a coil formed by winding a coil wire; and an insulating member. The coil includes a first wound portion and a second wound portion, the first wound portion being formed to surround the winding axis, the second wound portion being formed at a position adjacent to the first wound portion on an outer perimeter side of the coil. The insulating member includes a first insulating portion configured to cover a perimeter surface of the first wound portion, and a second insulating portion configured to cover a perimeter surface of the second wound portion. A portion of a surface of the first insulating portion located on the outer perimeter side of the coil is in contact with a portion of a surface of the second insulating portion located on the winding axis side.

First claim

What is claimed is:

1. A coil module comprising:
a coil formed by winding a coil wire so as to surround a winding axis and get away from the winding axis as the coil wire extends from one end toward the other end; and
an insulating member formed to cover a perimeter surface of the coil wire when the coil wire is cross-sectionally viewed along a cross section perpendicular to a direction of extension of the coil wire, and formed to extend from the one end to the other end of the coil wire,
when the coil is cross-sectionally viewed along the cross section perpendicular to the direction of extension of the coil wire, the coil including a first wound portion and a second wound portion, the first wound portion being formed to surround the winding axis, the second wound portion being formed to surround the winding axis and formed at a position adjacent to the first wound portion on an outer perimeter side of the coil,
the insulating member including a first insulating portion configured to cover a perimeter surface of the first wound portion, and a second insulating portion configured to cover a perimeter surface of the second wound portion,
a portion of a surface of the first insulating portion located on the outer perimeter side of the coil being in contact with a portion of a surface of the second insulating portion located on the winding axis side, thereby spacing the first wound portion and the second wound portion apart from each other by a predetermined distance, wherein
a recess is formed in one of the portion of the surface of the first insulating portion located on the outer perimeter side of the coil and the portion of the surface of the second insulating portion located on the winding axis side, and
a protrusion inserted into the recess is formed on the other of the portion of the surface of the first insulating portion located on the outer perimeter side of the coil and the portion of the surface of the second insulating portion located on the winding axis side.

2. The coil module according to claim 1 , further comprising
a mold resin configured to cover the coil and the insulating member.

3. A coil unit capable of at least one of power reception from an external coil unit provided outside and power transmission to the external coil unit,
the coil unit comprising the coil module as recited in claim 1 .

4. A coil module comprising:
a coil formed by winding a coil wire so as to surround a winding axis and get away from the winding axis as the coil wire extends from one end toward the other end; and
an insulating member formed to cover a perimeter surface of the coil wire when the coil wire is cross-sectionally viewed along a cross section perpendicular to a direction of extension of the coil wire, and formed to extend from the one end to the other end of the coil wire,
when the coil is cross-sectionally viewed along the cross section perpendicular to the direction of extension of the coil wire, the coil including a first wound portion and a second wound portion, the first wound portion being formed to surround the winding axis, the second wound portion being formed to surround the winding axis and formed at a position adjacent to the first wound portion on an outer perimeter side of the coil,
the insulating member including a first insulating portion configured to cover a perimeter surface of the first wound portion, and a second insulating portion configured to cover a perimeter surface of the second wound portion,
a portion of a surface of the first insulating portion located on the outer perimeter side of the coil being in contact with a portion of a surface of the second insulating portion located on the winding axis side, thereby spacing the first wound portion and the second wound portion apart from each other by a predetermined distance, wherein
in a direction of extension of the winding axis, a distance between an outer surface of the insulating member and the coil is longer than a distance between the first wound portion and the second wound portion.

5. The coil module according to claim 3 , further comprising
a mold resin configured to cover the coil and the insulating member.

6. A coil unit capable of at least one of power reception from an external coil unit provided outside and power transmission to the external coil unit,
the coil unit comprising the coil module as recited in claim 4 .

Assignees

• Toyota Motor Co Ltd

Inventors

• Doi Taiga

Classifications

• H01F27/363

  made of electrically conductive material · CPC title

• H01F38/14

  Inductive couplings {(for wireless supply or distribution of electric power using inductive coupling H02J50/10)} · CPC title

• H01F27/40

  Structural association with built-in electric component, e.g. fuse · CPC title

• H02J50/10 Primary

  using inductive coupling · CPC title

• H01F27/36

  Electric or magnetic shields or screens (movable for varying inductance H01F21/10) · CPC title