JP2003134758A - Method for manufacturing centralized distribution member of thin brushless motor for vehicle - Google Patents

Abstract

PROBLEM TO BE SOLVED: To comparatively easily manufacture a centralized distribution member at a low cost. SOLUTION: An insulating holder that holds busbars is arranged in a cavity of an insert-forming metal mold. In this state, a molten resin material 90 for forming an insulating resin layer 25 is fed into the cavity 73. Circumferences of the busbars 22a, 22b and 22c and the insulating holder 21 are thereby coated with the insulating resin layer 25.

Description

Description: BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a thin brush for a vehicle.
The present invention relates to a method for manufacturing a centralized power distribution member of a motor.
You. 2. Description of the Related Art In recent years, there has been a need for lower fuel consumption of vehicles.
Large, one example is an ultra-fuel-efficient hybrid car
Is being developed. Especially recently, engine
Powered by DC brushless motor for acceleration
Equipped with an auxiliary power mechanism (motor assist mechanism) to assist
Hybrid cars have been proposed. [0003] By the way, a motor assist mechanism is constructed.
Brushless motors have limited space in the engine room.
Source, specifically between the engine and the transmission
Placed in a narrow space, imposes great restrictions on installation.
receive. Therefore, this type of brushless motor is thin and
It is required to be. [0004] A thin vehicle for use in a motor assist mechanism
Type brushless motor is used for the crankshaft of the engine.
A directly connected rotor and a ring-shaped
And a stator. The stator is wound around the core.
Houses many magnetic poles and magnetic poles formed by applying wires
To distribute power intensively to the stator holder and windings
Consisting of centralized distribution members (so-called bus rings)
Have been. Conventionally, thin brushless motors for vehicles have been concentrated.
When manufacturing power distribution members, U, V, W, three phase
Each subbar is individually ring-shaped using a separate mold.
It was punched out. And on the surface of these busbars
Forming insulating film by applying fluororesin coating
Layer in the thickness direction (center axis direction)
Data side. [0006] However, in the past,
Because the ring-shaped busbars were separated into three phases,
Many parts to assemble them into one member
It was necessary and the assembly work was troublesome. Also, the bus bar
There is also a problem with the insulation between
Repeat the coating to form a thick insulating film
Needed. Therefore, the production of the centralized distribution member becomes complicated.
Therefore, there has been a problem that the manufacturing cost has risen. The present invention has been made in view of the above problems.
The aim is low cost and relatively easy to manufacture
Of a centralized power distribution member for thin brushless motors for vehicles
It is to provide a manufacturing method. Means for Solving the Problems According to the invention of claim 1,
Are connected to the terminals connected to the battery and the windings of the stator.
It has tabs to be connected and corresponds to each phase of the motor.
Multiple annular busbars, and the busbars
-Hold grooves that hold each other at a predetermined interval
Covers the edge holder and each of the bus bars and the insulating holder
Resin insulating layer,
A method for manufacturing a ring-shaped centralized distribution member capable of distributing a flow
Thus, the insulating holder holding each bus bar is
And placed in the cavity of the molding die.
Supplying the resin for forming the resin insulating layer into the cavity
By doing so, the insulating holder together with each of the bus bars
The gist is to perform insert molding. According to the first aspect of the present invention, a plurality of buses are provided.
Hold the bars together in one insulating holder and insert it
It has a sert molding. Therefore, multiple busbars
Without using many parts to assemble,
The attaching work is also easy. Also, resin molding layer and insulating holder
The insulation between the busbars is achieved by
Eliminating the need for Therefore, relatively simple and low cost
The centralized distribution member can be manufactured by the strike. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS One embodiment of the present invention will now be described.
An embodiment will be described with reference to the drawings. As shown in Figure 1
Three-phase thin DC used in hybrid vehicles
The brushless motor 11 is connected to the engine 12 and the transmission.
It is arranged between the communication terminal 13. Thin brushless model
Motor 11 is directly connected to the crankshaft of the engine 12.
Rotor 14 and a ring shape surrounding the rotor 14
And the stator 15. The stator 15 has a core
Magnetic poles formed by applying a winding 16 to the
The power is distributed to the stator holder and the windings 16 accommodating the poles.
The centralized distribution member 17 and the like.
You. FIG. 2 shows a schematic diagram of the stator 15. It is shown in the figure
As described above, one end of the winding 16 of each phase is
Connected to the bus bars 22a, 22b, 22c
And the other end is connected to a ring-shaped conductive member (not shown).
I have. As shown in FIG. 3 to FIG.
7 is a continuous ring made of natural color synthetic resin inside
Of the insulating holder 21 is embedded. Insulation holder 21
As a forming material, for example, PBT (polybutylene tereph
Tarates: polybutyrene terephthalate) and PPS
(Polyphenylene sulfid: polyphenylene sulfid
e) etc. can be used. In this embodiment, the material for forming the insulating holder 21
PPS made by adding about 40% glass fiber
ing. The reason for using this material for the insulating holder 21 is as follows.
This is because they have excellent electrical characteristics (dielectric strength).
You. In particular, in the thin brushless motor 11 of the present embodiment,
Is applied to the bus bars 22a, 22b, 22c of each phase.
Voltage is high, the bus bars 22a, 22b, 2
It can be said that it is important to ensure a dielectric strength of 2c.
In this case, the withstand voltage should be at least 2000 V or more.
Top is required. In addition, PPS is, for example, PP (poly)
Extremely high heat resistance compared to general-purpose resins such as propylene)
Not only that, it also has excellent mechanical strength. As shown in FIG. 8, FIG. 9 and FIG.
On one side of the rudder 21, there are three extending along its circumferential direction.
Holding grooves 23a, 23b and 23c are recessed. each
The holding grooves 23a, 23b, 23c are spaced at parallel intervals, respectively.
Are arranged in parallel in the radial direction of the insulating holder 21.
Each holding groove 23a, 23b, 23c has
Corresponding bus bars 22a, 22b, 22c are inserted individually
Have been. Each bus bar 22a, 22b, 22
c is the diameter of the centralized distribution member
They are arranged in a stack. Therefore, the holding grooves 23a, 23b,
Each of the inserted bus bars 22a, 22b, 2
There is a role of relative holding 2c in an accurate position. And
The insulating holder 21 and each bus bar 22a, 22b, 2
2c is entirely covered with the insulating resin layer 25.
You. With this coating, the bus bars 22a, 22b, 22c
Is insulated. The insulating resin layer 25 is in contact with the insulating holder 21.
The same is made of PPS to which glass fiber is added. This material
The reason why the material was used for the insulating resin layer 25 is that
For the same reason as in the case of FIG.
This is because heat resistance and mechanical strength are excellent. However,
The material of the edge resin layer 25 is also natural color natural resin.
Have been. In this embodiment, the bus located inside is
The bar 22a is in the W phase, and the bus bar 22b in the middle is in the U phase.
Bus bar 22c located on the outside corresponds to the V-phase.
You. In the following, for the sake of simplicity, the W-phase bus
Bar 22a is referred to as "inner bus bar 22a", U-phase bus bar
22b is an “intermediate bus bar 22b”, and the V-phase bus bar 22
c is expressed as "outer bus bar 22c" to be distinguished. Each of the bus bars 22a, 22b, 22c
Will be explained. The bus bars 22a, 22b, 22c are:
Pressing a conductive metal plate made of copper plate or copper alloy
The thickness of the strip-shaped molding material punched into
In an incomplete ring shape (substantially C
(Shape). In addition, each bus bar 22
a, 22b, and 22c are larger as the outer diameter is larger.
It is set to be easy. Then, each shaped bar
Each of the sub-bars 22a, 22b, 22c is
3b and 23c, the insulating holder 21
Of the bus bars 22a, 22b, 22c
It's easy. As shown in FIG. 8 to FIG.
2a, 22b, 22c, one side edge of the winding 16
A plurality of tabs 41a, 41b, 41c to which the ends are connected project.
Is established. Each tab 41a, 41b, 41c is a bus
It is a material for forming the bars 22a, 22b, 22c.
When punching conductive metal sheet material with a press machine,
It is punched at the same time. Therefore, the bus bar 22
a to 22c and tabs 41a to 41c are pressed once.
Process, they are integrally formed in a connected state.
You. This is because the bus bars 22a, 22b, 22c and the tab 4
When attaching to 1a, 41b, 41c by welding etc.
Because the manufacturing process can be simplified compared to
You. Each tab 41a, 41b, 41c
Is 6 pieces for each bus bar 22a, 22b, 22c.
One is provided. Tabs 41a, 41 for each phase
b, 41c are circles of each bus bar 22a, 22b, 22c.
At equal intervals along the circumferential direction, that is, with a central angle of 60 °
Is placed. Then, cut off each of the bus bars 22a to 22c.
The separation parts 42 are arranged at a distance of 20 ° from each other in the circumferential direction.
Thus, a total of 18 tabs 41a to 41c are collected.
Along the circumferential direction around the center of the middle power distribution member 17
They are arranged at equal intervals, that is, at a central angle of 20 °.
Incidentally, in this embodiment, as shown in FIG.
When the separation part 42 of the subbar 22c is used as a reference,
The bus bar 22b is shifted + 20 ° in the clockwise circumferential direction.
Are located. On the other hand, the inner bus bar 22a
Are offset by -20 ° in the counterclockwise direction. Tab of each bus bar 22a, 22b, 22c
41a, 41b, 41c are the tips of the centralized distribution member 17
Each of them is bent in a substantially L-shaped section so as to face the center.
You. And, the tip of each tab 41a, 41b, 41c
Protrudes outward from the inner peripheral surface of the centralized power distribution member 17.
You. The winding 16 is connected to this protruding portion.
Swelling. Each tab 41a, 41b, 41c
Each length is different and their tips are
Are located on the same circumference with the center of the member 17 as the center.
You. For this reason, the bus bars 22a, 2
Tabs 41a, 41b and 41c of 2b and 22c are concentrated
The length in the radial direction of the power distribution member 17 is long. As shown in FIG. 15A and FIG.
In the insulating resin layer 25 at the tab 41b of the bus bar 22b
The portions covered by the holding grooves 23a, 23b,
Walls 43a, 43b, 43c, 43d constituting 23c
The curved part 44 which swells in the height direction is formed. this
The curved portion 44 is connected to the inner bus bar in the insulating resin layer 25.
22a (another bus bar) bypasses the upper edge. this
The reason why the curved portion 44 is provided is to secure the creepage distance.
You. As shown in FIGS. 16A and 16B, the outer side
In the insulating resin layer 25 at the tab 41c of the bus bar 22c
In the places covered with more, the height of the wall portions 43a to 43d
A curved portion 45 bulging in the vertical direction is formed. This curvature
The portion 45 is formed inside the insulating resin layer 25 by the inner bus bar 22.
a as well as the intermediate bus bar 22b (all other bus bars).
-) It bypasses the upper edge. This curved portion 45 was provided.
Is to secure the creepage distance in the same manner as the above-described curved portion 44.
That's why. In addition, the bending part 45 here has two buses.
Because the upper ends of the bars 22a and 22b are bypassed,
The bent portion 44 of the tab 41b on the intermediate bus bar 22b
Longer. As shown in FIGS. 14A and 14B,
The base end of the tab 41a on the bus bar 22a is as described above.
There are no such curved portions 44 and 45, and simply bends at 90 °
Shape. This is because the tab 41a is bent.
There is no other bus bar on the side where
This is because there is no need to secure separation. As shown in FIGS. 14A and 14B, the inner side
Tab forming portion of bus bar 22a and inner bus bar 2
Tab non-forming portion of the intermediate bus bar 22b adjacent to 2a
At the end of the wall 43b that separates
It is formed integrally. The inner small projection 47 was provided.
Is the inner bus bar 22a and the intermediate bus bar adjacent to it.
This is to ensure a creepage distance between the first and second surfaces 22b. Inside small
The projecting pieces 47 are made of synthetic resin and provided in total of six.
And they are equally spaced along the circumferential direction of the insulating holder 21
It is arranged at a distance. And each inner small protruding piece 47 is
To each tab 41a provided in the side bus bar 22a
One by one. It also has an inner small projection 47.
The height of the wall 43b is determined by the inner bus bar 22a and the intermediate bus.
Wall portion 43 separating tab-free portions of bar 22b
It is higher than the height of b. As shown in FIGS. 15A and 15B,
Tab forming portion of bus bar 22b and intermediate bus bar 2
Tab non-forming portion of the outer bus bar 22c adjacent to the outer bus bar 2b;
At the end of the wall 43c that separates
It is formed integrally. The outer small piece 48 was provided.
Is the intermediate bus bar 22b and the outer bus bar adjacent thereto
This is for ensuring the creepage distance between the first and second members 22c. Outside small
The protruding pieces 48 are made of synthetic resin, and are provided in total of six.
And they are equally spaced along the circumferential direction of the insulating holder 21
It is arranged at a distance. And each outer small protruding piece 48 is
To each tab 41b provided in the bus bar 22b
One by one. In addition, it has an outer small protrusion 48.
The height of the wall 43c is determined by the intermediate bus bar 22b and the outer bus.
Wall portion 43 separating tab non-formed portions of bar 22c
It is higher than the height of c. As shown in FIG. 3 to FIG.
a, 22b, and 22c are provided with terminal portions 50, respectively.
w, 50u, 50v are integrally formed one by one,
Are protruded from a part of the outer peripheral surface of the insulating resin layer 25.
The terminals 50u, 50v, and 50w are connected to the power supply cable shown in FIG.
Cable of the thin brushless motor 11 through the cable 51.
It is connected to a battery (not shown). Each terminal section 50
u, 50v, 50w are the bus bars 22a, 22b, 22
Pressing conductive metal sheet material, which is the material when molding c
When punching with the device, it is punched at the same time
is there. Therefore, the bus bars 22a to 22c and the terminal 50
u, 50v, 50w means going through one pressing process
And are integrally formed in a connected state. This is a bus
Bars 22a, 22b, 22c and terminal portions 50u, 50v,
Manufacture in comparison with the case where 50w is retrofitted by welding etc.
The process can be simplified. As shown in FIGS. 6 and 7, the terminal portions 50u,
At the tip of 50v, 50w, the power cable 51
A bolt insertion hole 52 through which a mounting bolt (not shown) is inserted is formed.
It is transparent. Each terminal is provided on the outer peripheral surface of the insulating resin layer 25.
From the base end to the center of the parts 50u, 50v, 50w
A resin container 53 surrounding the periphery is integrally formed.
Made of thermosetting resin with insulating properties
The sealing material 54 is filled. Then, the terminal portions 50u,
50v, 50w, the base end than the bolt insertion hole 52
On the side and exposed from the insulating resin layer 25 are sealed
It is buried by the material 54. Each sealing material 54
To seal a part of the terminal portions 50u, 50v, 50w
Thus, waterproofness and airtightness are improved. In this embodiment
In addition, a silicone-based thermosetting resin is used as the sealing material 54.
I'm using Thermosetting resin is optional other than silicone type
It is possible to change to FIG. 28 shows the bus bars 22a, 22b, 22
It is the figure which expanded c. As shown in FIG.
u, 50v, 50w are the bus bars 22a, 22b, 2
It is arranged at a substantially central portion in the longitudinal direction of 2c. Soshi
On both sides of each terminal 50u, 50v, 50w
The number of certain tabs 41a, 41b, 41c is the same
You. More specifically, each terminal unit 50u, 50v, 50w
Is provided with three tabs 41a, 41b, 41c on one side
And three tabs 41a, 41b, 41c on the other side.
Is provided. Thus, the terminal portions 50u, 50v,
The same number of tabs 41a, 41 on both sides of 50w
The tabs 41a, 41b, 41c are provided with b, 41c.
This is because a current equal to As shown in FIGS. 6 and 8, each terminal 50u
To 50 w are covered with the sealing material 54 at the base end thereof.
With the embedded portion 55 and the bolt insertion hole 52
And an exposed portion 56 not covered by the material 54.
It is. The buried portion 55 is press-formed, and the central portion thereof is inclined.
It is bent in a shape. Thus, the inclined portion 55a is formed.
The reason is that the central part of the buried part 55 is bent at a right angle.
Can also use less material, and the busbar 22
This is because it contributes to the weight reduction of a, 22b, and 22c. In each terminal unit 50u, 50v, 50w
Slits 57a and 57b are formed at both ends of the buried portion 55, respectively.
Is established. Both slits 57a and 57b are connected to the terminal 5
0u, 50v, and 50w extend along the longitudinal direction.
The buried portion is formed by the two slits 57a and 57b.
Part of 55 will be cut off, and in that part
The width of the embedded portion 55 is smaller than the width of the
Has also become shorter. Such a configuration is
Insulation covering the periphery of the insulating holder 21 by heat molding
When the resin layer 25 is cooled, the insulating resin layer 25 and the bus bar
22a to 22c to reduce the difference in the amount of heat shrinkage.
You. The number and width of the slits 57a and 57b are determined by each terminal.
The strength of the parts 50u, 50v, 50w is not impaired.
If it is, it can be arbitrarily changed. For example, buried part
55, two slits 57a, 57b at each end
Can be provided. As shown by cross hatching in FIG.
u, 50v, 50w, the exposed portion 56 and the buried portion 55
Are plated with tin. See Exposure
Of the oblique portion 55a in the embedded portion 55 from the tip of the portion 56
Tin plating is applied near the center. This tin
The reason I did it was that the bus bars 22a, 22b, 22c
This is to prevent the surface from being oxidized and corroded. The terminal portions 50u, 50v, and 50w are shown in FIG.
8. After bending by the first press device 60 shown in FIG.
Next, the second press device 61 shown in FIG.
It is obtained by doing. First, the first press device 60 will be described.
You. As shown in FIGS. 18 and 19, the first pressing device 60
Is to bend the terminals 50u, 50v, 50w
It is. The first pressing device 60 includes a fixed lower die 62.
And an upper die 63 which is a movable die. Soshi
As the upper die 63 approaches the lower die 62,
62 and 63 are closed. On the other hand, from the lower mold 62
When the upper mold 63 is separated, both molds 62 and 63 are opened. On the upper surface of the lower mold 62, a V-shaped lower mold side component is formed.
And a V-shaped lower mold side forming protrusion 62b.
Are formed adjacent to each other. Lower mold side forming protrusion 62
A pilot pin 64 protrudes from the upper end of b.
You. The pilot pins 64 are connected to the terminal portions 50u, 50
Pilot hole penetrated in the slanted portion 55a of v, 50w
65, the terminal portions 50u, 50v, 50w
Is positioned. On the other hand, the lower surface of the upper die 63 has a V-shape.
Upper mold side forming protrusion 63a and V-shaped upper mold side forming recess
63b are formed adjacent to each other. Upper mold side molding
The protrusion 63a and the lower mold side forming recess 62a face each other,
One upper mold side forming concave portion 63b and lower mold side forming protrusion 62b
Are facing each other. Therefore, the lower mold 62 is attached to the upper mold 6.
3 closes the mold and closes the mold.
The two dies 62 and 63 are engaged with each other.
You. In addition, on the inner inner surface of the upper mold side forming concave portion 63b, a retracting concave portion is provided.
A part 66 is formed. Then, both dies 62 and 63 are closed.
When it is twisted, the pilot pin
64, the pilot pin 64 and the upper die 6 are inserted.
3 do not interfere with each other. Next, the second press device 61 will be described.
I do. As shown in FIG. 20, the second pressing device 61 has a terminal
Parts 50u, 50v, 50w and bus bars 22a, 22b,
The boundary portion with 22c is formed by bending. 2nd pre
The device 61 is a fixed lower die 67 and a movable die.
An upper mold 68 is provided. Then, the lower mold 67
As the upper mold 68 approaches, both molds 67 and 68 close.
Can be On the other hand, the upper mold 68 is separated from the lower mold 67.
As a result, both molds 67 and 68 are opened. On the upper surface of the lower mold 67, terminal portions 50u, 50
v, 50w lower mold side molding in which the buried portion 55 is engaged
A protrusion 67a is formed. Lower mold side in lower mold 67
The terminal portion 50 is located near the molding protrusion 67a.
Insertion pin 69 for positioning u, 50v, 50w
Is protruding. The terminal portions 50u, 50v,
When 50w is set, it is inserted into the bolt insertion hole 52.
The input pin 69 is penetrated. Insertion pin 6
In the state where 9 has penetrated, the terminal portions 50u, 50v, 50w
Does not shift. On the lower surface of the upper die 68, a lower die side forming projection 67 is provided.
The upper mold-side molding concave portion 68a facing a is formed.
Then, the upper mold 68 approaches the lower mold 67 to close the mold.
, The relationship between the concavities and convexities of the two portions 67a and 68a.
As a result, both molds 67 and 68 come into engagement with each other
I have. The upper mold 68 excluding the upper mold side forming recess 68a is
Insertion pin 6 on lower mold 67 when both molds 67, 68 are closed
The thickness is set so as not to interfere with No. 9. As shown in FIG. 18B and FIG.
By the first press device 60 and the second press device 61,
A part where bending processing is performed on the terminal parts 50u, 50v, and 50w.
The notch 59 has a plurality of notches 59 extending in the width direction.
Have been. The notch 59 is connected to the terminal portions 50u, 50v,
Before forming 50w, punched conductive metal plate
Are provided on both sides of the belt-shaped molding material 92, respectively.
You. In the present embodiment, the terminal portions 50u, 50v, 50w
One is provided on one surface of the corresponding band-shaped molding material 92,
Three are provided on the other surface. And the band-shaped molding material
The portion where the notch 59 is recessed at 92 is bent inward.
Can be Next, the first press constructed as described above
Terminal unit 50 using the device 60 and the second pressing device 61.
The step of bending u, 50v, and 50w will be described. Figure
18 (a) and 18 (b), the first pressing device 60
With both dies 62 and 63 open, the upper die 62
Plate-shaped strip formed by punching conductive metal sheet into specified shape
The material 92 is placed. Then, the band-shaped molding material 92
The pilot of the lower mold 62 is inserted into the formed pilot hole 65.
The pin 64 is made to penetrate, and the band-shaped molding material 92 is not displaced.
To be. Furthermore, the bolt in the band-shaped molding material 92
The end having the insertion hole 52 is engaged with the lower mold 62.
This also prevents the same band-shaped molding material 92 from being displaced.
To do. As shown in FIGS. 19A and 19B, both types
When the belts 62 and 63 are closed, the belt-shaped molding material 92 is
Between the side molding recess 62a and the upper mold side molding projection 63a, the lower mold
Sandwiched between the side molding protrusion 62b and the upper mold side molding recess 63b.
Be included. Thereby, the terminal portions 50u, 50v, 50w
Is bent at the portion corresponding to
50u, 50v, 50w are formed. After that, both types 6
2, 63 are opened, and terminal portions 50u, 50v,
The strip-shaped molding material 92 in which only 50 w is molded is taken out.
You. Next, as shown in FIGS.
In the state where both dies 67 and 68 of the second press device 61 are opened
Then, the first pressing device is inserted into the lower mold side forming concave portion 62a of the lower mold 62.
The terminal portions 50u, 50v, 50w formed by the
Combine. At the same time, the terminal portions 50u, 50v, 50w
The insertion pin 69 passes through the bolt insertion hole 52 formed in
To prevent the belt-shaped molding material 92 from being displaced. Then, when both molds 67 and 68 are closed,
Ends of the band-shaped molding material 92, that is, the bus bars 22a, 22
The parts corresponding to b and 22c are the lower mold side forming projection 67a.
It is sandwiched between the upper mold side forming recess 68a and the gap. to this
The bus bars 22a, 22b, 22c and the terminal 50
The boundary with u, 50v, 50w is bent at a right angle.
Thereafter, the two dies 62 and 63 are opened, and the terminal 5
Band-shaped molding material 9 in which only 0u, 50v, and 50w are molded
2 is taken out. As shown in FIGS. 24 to 27, the insulating holder
The insulating resin layer 25 covering the base 21 is made of insert molding metal.
Molded by the mold 70. This insert molding die
70 is a fixed lower mold 71 and a movable upper mold 7.
And 2. Upper mold 72 is lower than lower mold 71
It can be approached and separated, and when the upper mold 72 approaches
The mold is closed and the mold is opened by separating. The lower mold 71 and the upper mold 72 are formed respectively.
The recesses 71a and 72a are formed so as to face each other.
Then, both molds 71 and 72 are closed by mold closing.
Ring formed by two concavities 71a, 72a facing each other
Cavity 73 is formed. This
Of the cavity 73 through a gate (not shown)
The molten resin material 90 for forming the oil layer 25 is filled.
You. The gate is provided on the inner peripheral surface of the lower mold 71 (FIGS. 24 to 2).
7 on the left side). And
The gates are evenly spaced along the inner peripheral surface of the lower mold 71.
It is provided in. Thereby, the inside of the cavity 73 is
And the pressure of the molten resin material 90 applied to the insulating holder 21 is
Be even. The upper die 72 is housed in the cavity 73.
Upper support 8 for pressing the upper surface of insulating holder 21
0 is provided. The upper die-side support 80 is
It can protrude and retract from the inner top surface of the shaped recess 72a. Illustrated
However, the upper mold side support 80 is plural (in this embodiment,
18) are provided. The upper mold side support 80 is a terminal part.
Except where 50u, 50v, 50w are located
Are arranged at equal intervals along the circumferential direction of the insulating holder 21.
ing. And when the upper mold side support 80 is projected
The plurality of locking grooves 81 recessed at the tip end face
Wall part 4 separating bus bar 22a and intermediate bus bar 22b
3b, the intermediate bus bar 22b and the outer bus bar 2
2c and engages with the upper end of the wall 43c. this
In the engaged state, the tip end surface of the upper mold side support 80 is
The upper ends of the bus bars 22a, 22b, 22c are in contact with each other.
You. As a result, the insulating mold is supported by the upper mold side support 80.
The upper side of the holder 21 (the upper side of the holder 21 shown in FIG. 24) is pressed.
It can be attached. The lower mold 71 is housed in the cavity 73.
As a holder support for supporting the insulating holder 21
A holder support pin 74 is provided. This holder support
The pin 74 extends from the vicinity of the bottom surface of the lower molding concave portion 71a.
It is possible to appear in the tee 73. Although not shown,
A plurality of (36 in this embodiment) rudder support pins 74 are provided.
And they are equally spaced along the circumferential direction of the insulating holder 21.
They are arranged at intervals. As shown in FIGS. 22, 23 (a) and 23 (b)
In the state where the holder support pin 74 is protruding,
The tip is a non-penetration formed on the lower surface of the insulating holder 21.
The recess 75 is engaged. With this engagement, the cavity 7
When the insulating holder 21 is accommodated in the
The dam 21 does not shift. The non-penetrating recess 75 is formed in a tapered shape.
And the diameter is reduced toward the inner top. So
Therefore, the holder support pin 74 is not
Is finally guided to the non-penetrating recess 75 by the holder support.
The holding pin 74 is engaged. Therefore, the lower molding of the lower mold 71
When setting the insulating holder 21 in the concave portion 71a, the holder
When the support pin 74 is displaced from the non-penetrating recess 75,
There is no. On the bottom surface of the insulating holder 21, a holder support
An arc-shaped rib 7 is provided at a position located around the holding pin 74.
6a and 76b are protruded. Ribs 76a, 76
b, the holder engaged with the non-penetrating recess 75
The support pins 74 do not come off easily. Between the ribs 76a and 76b, a plurality (actual
In the embodiment, two notches 77a and 77b are formed.
ing. The presence of these notches 77a, 77b
Non-penetrating during insert molding of the insulating resin layer 25
In a state where the holder support pin 74 is pulled out from the concave portion 75,
It is cut off to the non-penetrating recess 75 side through the notches 77a and 77b.
The resin for molding the edge resin layer 25 is easily turned around.
You. In the finally manufactured centralized distribution member 17, non-penetrating
The recess 75 is filled with the insulating resin layer 25.
The ribs 76a, 76b and the notches 77a, 77b
Can be arbitrarily changed. For example, rib 7
6a and 76b are reduced to one, and the overall shape is C
The notch portions 77a and 77b are made into one
It is possible to As shown in FIG. 22, FIG. 23, and FIG.
As described above, the holding grooves 23a, 2
A communication hole 78 communicating with the inside of each of 3b and 23c is provided.
You. The reason why the communication hole 78 is provided is that the insulating resin layer 25 is formed.
For the holding grooves 23 during the insert molding.
a, 23b, 23c in order to make it easier to
You. The communication hole 78 is formed along the circumferential direction of the insulating holder 21.
Several are provided. To be precise, each communication hole 78
Along each holding groove 23a, 23b, 23c
Each is arranged. Moreover, as shown in FIG.
The communication holes 78 are mutually connected in the circumferential direction of the insulating holder 21.
The positions are shifted. This means that
One communication hole 7 is located on the same line in the radial direction of the
It means that only 8 are arranged. As shown in FIGS. 22 and 24, the lower mold 71 is
When the insulating holder 21 is set, the lower molding recess 71a
Positioning projection 82 against which the front end surface abuts against the inner surface of
Are formed on the inner peripheral surface of the insulating holder 21. This position
A plurality of fixing protrusions 82 are provided, and they are insulating holders.
21 are arranged at regular intervals along the circumferential direction. all
Of the positioning protrusion 82 protrudes from the inner surface of the lower molding recess 71a.
The contact causes the insulating holder 21 to move in the radial direction.
No misalignment occurs. As shown in FIG. 9, FIG. 12, and FIG.
Each of the holding grooves 23a to 23c in the holder 21 is a bus bar.
Busbar accommodation part 83 in which 22a to 22c are accommodated
And non-accommodated busbar non-accommodated parts 84
Is done. Holding groove 23 in busbar non-accommodating portion 84
a, 23b, and 23c, a plurality of first reinforcing ribs 85 are provided.
The insulating holder 21 is provided at intervals in the circumferential direction.
You. Each of the first reinforcing ribs 85 includes a holding groove 23a, 23b, 2
3c and the bottom and inner surfaces of the walls 43a to 43d.
It is formed physically. Note that the holding grooves 23a, 23b and 23c
The communication hole 78 that facilitates the flow of the molten resin material 90 is
Holding grooves 23a, 23 located at respective portions 83, 84
b, 23c. This keeps
The entire groove 23a, 23b, 23c is filled with the molten resin material 90.
It becomes easy to be filled. Busbar accommodation site in insulating holder 21
83 is provided with three holding grooves 23a, 23b, 23c.
In contrast, the busbar non-accommodating portion 84 has two
Only the holding grooves 23a and 23b are provided. That is,
In the busbar non-accommodating portion 84, the outermost
There is no holding groove 23c. For this reason, the insulating holder 21
The busbar non-accommodating portion 84 that is
It is narrower than. Further, the busbar collection in the insulating holder 21 is performed.
A second reinforcing rib 86 is provided on the outer peripheral surface of
The projection 21 is provided so as to extend along the circumferential direction of the die 21.
The second reinforcing rib 86 is formed in an arc shape, and has a curvature.
The radius is set to be the same as the radius of the insulating holder 21. Next, the insert constructed as described above is used.
Insert the centralized power distribution member 17 using the molding die 70
The method of molding will be described. With the mold open,
Place the insulating holder 21 in the lower molding recess 71a of the mold 71.
You. Then, the non-penetrating concave portion 75 of the insulating holder 21 is
Holder support pin 74 protruding into molding recess 71a
Engages the tip of Thereby, the insulating holder 21 is on the lower side.
It is supported at a fixed distance from the bottom of the molding recess 71a.
The Rukoto. At this time, the
Each of the plurality of positioning projections 82 has a tip surface formed with a lower molding concave.
It is in contact with the inner peripheral surface of the portion 71a. Therefore, insulation
The displacement of the rudder 21 in the radial direction is restricted. As shown in FIG. 24, the upper mold 72 is
When the mold is closed close to the cavity, a cavity 73 is formed.
Is done. At the same time, it protrudes into the upper molding recess 72a.
The front end surface of the upper die-side support body 80 that has been
It contacts the upper ends of 2b and 22c. Furthermore, the upper mold side support 8
The locking groove 81 at the front end surface of the holding groove 23a, 23b,
Engage with walls 43b and 43c that partition 23c. to this
From the insulating holder 21 and the bus bars 22a, 22b, 2
2c is pressed down by the upper mold-side support member 80. Less than
As described above, the insulating holder 21 includes a plurality of holder support pins.
74 and a plurality of upper mold side supports 80 in the vertical direction.
Movement is regulated. As shown in FIG. 25, the lower mold 71 is formed.
Through a gate (not shown) into the cavity 73.
The molten resin material 90 for forming a fat layer is filled. This and
The molten resin material 90 is directed toward the inner peripheral surface of the insulating holder 21.
At the same time from the gates arranged at equal intervals.
Then, a molten tree filled so as to cover the insulating holder 21.
The grease material 90 has openings in the holding grooves 23a, 23b, 23c.
It goes around inside through the part. Moreover, the insulation holder
The holding grooves 23a, 23 are
b, 23c. Also, in the insulating holder 21
Groove 23 of busbar non-accommodating portion 84 (see FIG. 12)
The pressure of the molten resin material 90 is applied to a, 23b and 23c.
However, the first and second reinforcing ribs 85 and 86 allow the wall portion 43 to be formed.
a to 43c are not deformed. The molten resin material 90 is substantially
At the end of the entire process, as shown in FIG.
The rudder support pin 74 is retracted to the lower mold 71 and the upper mold
The side support 80 retracts to the upper mold 72. At this time,
The rudder 21 is supported in the cavity 73.
Is completely floating, but the molten resin material
90 is continuously filled in the cavity 73,
The edge holder 21 does not tilt. In addition, the holder support pin
Pull-out due to the retreat of the upper mold 74 and the upper mold side support 80.
The hole is filled with the molten resin material 90. Furthermore, a holder
In the non-penetrating recess 75 with which the support pin 74 was engaged,
As the molten resin material 90 wraps around, the wall 43
b, 43c between and near the upper end portions of the molten resin material 90.
Turns around. Thereby, the insulating holder 21 is made of a molten resin material.
Covered by a charge 90. As shown in FIG. 27, a predetermined time has elapsed,
The molten resin material 90 is cooled and solidified to form the insulating resin layer 25.
Is molded. Then, the upper mold 72 is separated from the lower mold 71.
And open the mold so that the insulating holder 21 and the insulating resin layer 25
The integrated power distribution member 17 is taken out. Next, a method of manufacturing the centralized power distribution member 17 will be described.
Will be explained. (Step of punching conductive metal plate) As shown in FIG.
Then, the conductive metal plate 91 is pressed by a press (not shown).
To form the bus bars 22a to 22c by bending.
The original band-shaped molding material 92 is manufactured. Each bus bar 2
The strip-shaped molding materials 92 of 2a, 22b, and 22c are linear.
As such, they can be punched out in parallel.
This is the case when the band-shaped molding material 92 is punched in an annular shape.
Has significantly improved the yield compared to
You. (First Bending Process for Bus Bar) FIG. 2
As shown in FIG.
u, 50v, 50w are replaced by
Bending by the first press device 60 and the second press device 61
Mold. (Second Bending for Bus Bar) FIG. 2
As shown in FIG. 9, the terminal portions 50u, 50v, 50w are formed.
In the completed strip-shaped molding material 92, the bus bars 22a,
The portions corresponding to 22b and 22c are curved in the thickness direction.
To form a substantially annular shape. This molding is shown
Do not use bending equipment. Thus, the insulation
Assemble bus bars 22a, 22b, 22c on die 21
Before, the bus bars 22a, 22b, 22c are provided in a substantially annular shape.
Shape it. (Bus Bar Inserting Step) As shown in FIG.
In addition, each busbar is
Insert 22a, 22b, 22c. Here, the insulation
Insert them in order from the one located outside the cylinder 21. One
Mari, outside bus bar 22c, middle bus bar 22b, inside
Insert in the order of the bus bar 22a. Insert in this order
Is inserted first from the busbar inside,
The busbar to be inserted is connected to the terminal of the busbar inserted earlier.
This is because insertion is prevented. (Third Bending for Bus Bar) FIG. 3
As shown in FIG. 1, each bus bar 22a-
22c, the tabs 41a, 41b, 4
1c so that each end faces the center of the insulating holder 21
And bend it. At this time, the intermediate bus bar 22b and
Regarding the outer bus bar 22c, a curved portion 44,
45 is formed. (Insert molding) As shown in FIG.
Insulation with bus bars 22a, 22b, 22c assembled
An insulating resin layer 25 is formed on the outer periphery of the holder 21. This
Regarding the shape, the insert molding die 70 already described
This is performed by a manufacturing method using After that, insert
Take out the centralized power distribution member 17 from the molding die 70 and finally
The sealing material 5 is provided in the resin housing portion 53 formed in the insulating resin layer 25.
Fill 4. Therefore, according to the present embodiment, the following
The effect can be obtained. (1) Absolute holding each bus bar 22a, 22b, 22c
Insert the edge holder 21 into the cavity of the insert mold 70
73, and in this state, an insulating tree is placed in the cavity 73.
Filling the molten resin material 90 for forming the fat layer 25
I have. Thus, the three bus bars 22a, 22b, 2
By assembling 2c into one insulating holder 21,
They are collectively insert molded. for that reason,
Parts points when assembling bus bars 22a, 22b, 22c
The number can be reduced. Therefore, the bus bar 22
a, 22b, 22c can be easily assembled
As a result, assembly efficiency can be improved. (2) Insulating holder 21 and insulating resin layer 25
The insulation between the bus bars 22a, 22b, 22c is
Teflon is added to these busbars 22a to 22c.
There is no need to apply an expensive insulating coating such as (R).
Therefore, it is possible to manufacture the centralized distribution member 17 at low cost.
it can. (3) Each phase bus bar 22a, 22b, 2
2c is held by an insulating holder 21 made of one member.
And they are covered with an insulating resin layer 25.
You. Therefore, for example, a plurality of arc-shaped resin parts are disconnected.
The number of parts is larger than when the edge holder 21 is configured.
The width can be reduced, and the cost can be reduced.
Wear. (4) A not-shown copy formed on the lower mold 71
The insulating resin layer 25 is formed in the cavity 73 through a number of gates.
Is filled with a molten resin material 90 for forming the resin. That
Therefore, the molten resin material 90 is placed in the cavity 73 in a short time.
Can be filled, can improve production efficiency
You. (5) Melting Filled in Cavity 73
The resin material 90 is an insulating material disposed in the cavity 73.
Filling is performed toward the inner peripheral surface of the holder 21. With it
The locations where the molten resin material 90 is filled are equally spaced.
Therefore, the molten resin material 90 for the insulating holder 21
Pressure can be equalized. Therefore, the insulating holder
Prevents 21 from shifting from where it is positioned
be able to. (Another Embodiment) The embodiment of the present invention is as follows.
It may be changed as follows. In the above embodiment, the insulating resin layer 25 is formed
The molten resin material 90 is transferred from the inside of the insulating holder 21 to the cavity.
Filled inside 73, but filled from outside of insulating holder 21
You may make it. Or, outside the insulating holder 21
The inside of the cavity 73 is filled with the molten resin material 90 from the inside and the inside.
It may be filled. In the above embodiment, one insulating holder 21 is used.
, But the holding grooves 23a, 23b, 23c
May be constituted by a plurality of arc-shaped resin parts having the following. This
In the case of, the holding grooves 23a, 23
b, 23c to busbars 22a, 22b, 22c
Into a continuous annular insulating holder 21 as a whole.
You. And when insert molding, multiple arc-shaped
An insulating holder 21 made of a resin member is used for insert molding.
It is set on the lower mold 71 of the mold 70, and the insulating
An insulating resin layer 25 is formed around the cylinder 21. In the above embodiment, the three-phase thin brushless
Although it was embodied in the motor 11, it was not limited to
May be embodied. In addition, the implementation of single-phase motor
With this, it is permitted to reduce the number of busbars and holding grooves to two.
Is accepted. The above embodiment is a thin DC brushless model.
Although the motor 11 is used, the AC brushless motor is
It is also acceptable to embody. Next, it is described in the claims.
In addition to the technical ideas listed above,
The technical ideas grasped below are shown below. (1) The insulating holder according to claim 1,
Are arranged so as to float in the cavity, and the
Position by sandwiching both sides of the insulating holder with the support
And then form an insulating resin layer in the cavity.
Supplies materials for If you do not follow this method,
Since the insulating holder is floating inside the
Evenly and reliably apply resin for molding the insulating resin layer around the
Can be coated. Therefore, concentrated distribution with high withstand voltage
The electric member 17 can be manufactured. (2) The method according to (1), wherein
The resin for forming the insulating resin layer is loaded from the inner peripheral side of the insulating holder.
Supplied into the cavity, and the resin is supplied from multiple locations.
Supplied. According to this method, an insulating tree is formed in the cavity.
The resin for forming the oil layer can be supplied in a short time. (3) In the above (2), the insulating resin
The resin for layer molding is kept for a certain distance from the inner circumferential direction of the insulating holder.
Feed into the cavity at a distance. This way
If the pressure of the resin supplied into the cavity is
It will be evenly applied to da. Therefore, supply the resin.
When the insulation holder is
It will not slip. (4) According to claim 1, (1) to (3)
To supply the resin to the cavity.
The grease has a color that can be distinguished from the material of the insulating holder
I have. With this configuration, insulating resin is applied to the entire centralized power distribution member.
Easy visual inspection of whether the layer is completely covered
Can be determined. As the color, for example, supply insulation tree
Lightness, such as making the grease layer white and the insulation holder black
Preferably, there is a difference. According to the present invention, the centralized power distribution member can be reduced in cost.
And can be manufactured relatively easily.

BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a schematic diagram of a thin brushless motor. FIG. 2 is a schematic wiring diagram of a thin brushless motor. FIG. 3 is a perspective view of a centralized power distribution member. FIG. 4 is a front view of a centralized power distribution member. FIG. 5 is a rear view of the centralized power distribution member. 6A is a sectional view of a centralized power distribution member, FIG. 6B is an enlarged view of a terminal portion, and FIG. 6C is an enlarged perspective view of a terminal portion. FIG. 7 is a plan view showing a terminal portion of the centralized power distribution member. FIG. 8 is a perspective view of an insulating holder. FIG. 9 is a front view in which a bus bar is inserted into an insulating holder. FIG. 10 is an enlarged front view showing a part of the insulating holder. FIG. 11 is a front view showing only a bus bar, omitting an insulating holder. FIG. 12 is an enlarged view showing a busbar non-accommodating portion in the insulating holder. 13A is a cross-sectional view taken along the line EE in FIG. 9, and FIG.
9 is a sectional view taken along line FF in FIG. 9, and FIG. 14A is a cross-sectional view taken along the line AA of FIG. 4, and FIG. 14B is a perspective view of the same. 15A is a cross-sectional view taken along the line BB of FIG. 4, and FIG. 15B is a perspective view of the portion. 16A is a cross-sectional view taken along the line CC of FIG. 4, and FIG. 16B is a perspective view of the same. 17A is a cross-sectional view taken along the line DD of FIG. 4, and FIG. 17B is a perspective view of the portion. 18 (a) is a cross-sectional view of the first pressing device with the mold opened, and FIG. 18 (b) is a band-shaped material to be press-formed there. 19 (a) is a cross-sectional view of a first press device in which a mold is closed, and FIG. 19 (b) is a band-shaped forming material pressed there. 20 (a) is a cross-sectional view of a second press device in which a mold is closed, and FIG. 20 (b) is a band-shaped forming material press-formed therein. 21 (a) is a band-shaped forming material before bending a terminal portion of a bus bar, and FIG. 21 (b) is a sectional view taken along the line HH. FIG. 22 is a rear view of the insulating holder. 23A is an enlarged view of a non-penetrating recess, and FIG. 23B is an enlarged perspective view of a non-penetrating recess. FIG. 24 is a cross-sectional view showing a mold for insert molding and showing a state where an insulating holder is set. FIG. 25 is a cross-sectional view showing a state where the molten resin material has been filled in the insert molding die, following FIG. 24; FIG. 26 is a cross-sectional view showing a state where the holder support pin and the upper mold-side support are retracted, following FIG. 25; FIG. 27 is a cross-sectional view showing a state where the insert molding die is opened, following FIG. 26; FIG. 28 is a view showing a manufacturing process of the centralized power distribution member, in which a conductive metal plate material is punched to obtain a band-shaped molding material. FIG. 29 is a view showing a manufacturing step following FIG. 28, in which a terminal portion of the bus bar is bent. FIG. 30 is a view showing a manufacturing step following FIG. 29, in which a bus bar is inserted into an insulating holder; FIG. 31 is a view showing the manufacturing step following FIG. 30, in which the tab of the bus bar is bent inward; FIG. 32 is a view showing a manufacturing step following FIG. 31, in which a part of the terminal portion is sealed with a sealing material; [Description of References] 11: thin brushless motor (motor), 15: stator, 16: winding, 17: concentrated power distribution member, 21: insulating holder, 22a, 22b, 22c: bus bar, 23a, 23
b, 23c: holding groove, 25: insulating resin layer, 41a, 41
b, 41c ... tab, 50u, 50v, 50w ... terminal part,
70: insert molding die, 73: cavity, 90
... Molten resin material (resin for forming resin insulation layer).

   ────────────────────────────────────────────────── ─── Continuation of front page    F term (reference) 5H604 AA02 BB01 BB14 BB17 CC01                       CC05 CC16 DA17 DB02 PB04                       PC03                 5H615 AA01 BB01 BB07 BB14 BB16                       PP01 PP15 RR01 SS10 SS13                       SS44 TT03 TT31

Claims (1)

Claims: 1. A plurality of annular bus bars having a terminal portion connected to a battery and a tab connected to a winding of a stator and provided for each phase of a motor, An insulating holder having a holding groove for holding the bus bars at predetermined intervals, and a resin insulating layer covering the bus bars and the insulating holder are provided, and current can be intensively supplied to the windings. A method for manufacturing a ring-shaped concentrated power distribution member, comprising: placing an insulating holder holding each of the bus bars in a cavity of an insert molding die; A method for producing a centralized power distribution member of a thin brushless motor for a vehicle, wherein the insulating holder is insert-molded together with the bus bars.