JP2006166598A - Brushless motor, brushless fan motor device, and manufacturing method for brushless motor - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a brushless motor wherein a stator unit can be easily assembled to a motor in motor assembling work. <P>SOLUTION: The brushless motor 10 includes: a rotor 20 so constructed that it has rotor magnets 24; a stator core 80 in which multiple stator coils 70 are so disposed that it is opposed to the rotor magnets 24 in the the rotating axis direction; and connection terminal units 60 for connecting the terminal portions of the multiple stator coils 70. In this brushless motor 10, the connection terminal units 60, multiple stator coils 70, and stator core 80 are integrally molded with a resin member. Therefore, the connection terminal units 60, multiple stator coils 70, and stator core 80 are prevented from parting from one another during assembling work for the brushless motor 10. <P>COPYRIGHT: (C)2006,JPO&NCIPI

Description

  The present invention relates to a brushless motor, a brushless fan motor device, and a method of manufacturing a brushless motor, and in particular, an axial gap type brushless motor and a brushless fan motor in which a rotor magnet and a stator coil are arranged to face each other in the rotation axis direction. The present invention relates to an apparatus and a method for manufacturing a brushless motor.

  Conventionally, in the technical field of brushless motors, it has been known to use a connection terminal unit in which a connection terminal frame (bus bar) is molded as a technique for connecting a multi-phase stator coil and an external lead wire (or drive circuit). (For example, refer to Patent Document 1). For example, in the example described in Patent Document 1, a plurality of connection terminal frames formed in an arc shape are arranged concentrically, and the connection terminals are integrated with the resin member by molding the plurality of connection terminal frames. A terminal unit (injection molded terminal block) is formed.

In this type of brushless motor, predetermined terminal portions of the stator coil are connected to the connection terminals of the respective phases formed in the connection terminal unit and the connection terminals of the neutral point by welding or the like. Further, the stator unit is integrally assembled by connecting the stator coils of the plurality of phases and the connection terminal unit in this way and connecting the stator core to the connection terminal unit.
Patent 2000-333400

  However, in general, in a brushless motor, a connection terminal unit, a multi-phase stator coil, and a stator core are assembled in a complex manner to form a stator unit. At this time, if the stator unit is not assembled so that the connection terminal unit, the multi-phase stator coil and the stator core are firmly fixed, the stator unit will be scattered during the final assembly operation of the brushless motor. was there.

  The present invention has been made in view of the above problems, and an object of the present invention is to provide a brushless motor, a brushless fan motor device, and a method of manufacturing a brushless motor that can easily assemble a stator unit to a motor during motor assembly work. It is to provide.

  In order to solve the above-mentioned problem, the invention according to claim 1 is a rotor having a rotor magnet, and a stator core in which a plurality of stator coils are arranged so as to face the rotor magnet in the rotation axis direction. And a connection terminal unit configured to have a connection terminal portion for connecting terminal portions of the plurality of stator coils, wherein the plurality of stator coils and the stator core are integrated with a resin member. It is characterized by being molded.

  Thus, according to the first aspect of the present invention, since the plurality of stator coils and the stator core are integrally molded with the resin member, the plurality of stator coils and the stator core are assembled during the assembly operation of the brushless motor. Can be prevented from being scattered. As a result, a unit composed of a plurality of stator coils and a stator core can be easily assembled to the motor body.

  At this time, as described in claim 2, the connection terminal unit, the plurality of stator coils, and the stator core may be integrally molded with a resin member. If it does in this way, it becomes possible to assemble | attach the unit which consists of a connection terminal unit, a some stator coil, and a stator core to a motor main body easily at the time of the assembly operation of a brushless motor similarly to the above.

  According to a third aspect of the present invention, the connection terminal unit, the plurality of stator coils, and the stator core are integrally molded with a resin member to form a single unit, and this mold is formed. The external mounting stay may be integrally formed with a resin member on the stator unit by molding. In this way, when the stator unit is formed by integrally molding the connection terminal unit, the plurality of stator coils, and the stator core with the resin member, the external mounting stay is simultaneously formed on the stator unit. It is not necessary to form the stay separately. As a result, the number of manufacturing steps can be reduced as compared with the conventional case, and the increase in the number of parts can be prevented, so that the manufacturing cost can be reduced.

  In this case, as described in claim 4, it is preferable that the external mounting stay is formed in the vicinity of the boundary of the plurality of stator coils in the stator unit. Here, when the external mounting stay is formed at the radially outer position of each of the plurality of stator coils in the stator unit, and the gate at the time of molding is on the rotation center axis of the stator unit, each stator coil and stator coil The resin flows from between the two and the resin flowing from both the left and right sides of the stator coil merge at the position where the external mounting stay is formed.

  The portion where the resin merges is generally called a weld. In this weld, the resin collides with resins coming from opposite directions in a semi-solid state, so the resin does not mix completely and cures while leaving the boundary. End up. This boundary portion is generally called a weld line, and if this weld line is formed on the external mounting stay, the appearance of the external mounting stay is impaired. Moreover, since the strength of the portion where the weld line is formed is low, if the weld line is formed on the external mounting stay, the strength of the external mounting stay may be reduced.

  Therefore, as described in claim 4, when the external mounting stay is formed in the vicinity of the boundary of the plurality of stator coils in the stator unit, the external mounting stay is not joined at the position where the external mounting stay is formed. Can be molded. Therefore, it is possible to improve the appearance of the external mounting stay and to secure the strength of the external mounting stay.

  According to a fifth aspect of the present invention, the connection terminal unit may be formed by integrating the connection terminal portion and the resin member by molding the connection terminal portion. If it does in this way, since the shape and position of a connection terminal part can be fixed with a resin member, handling of a connection terminal unit can be made easy at the time of assembly work of a brushless motor, and it is suitable.

  As in the invention described in claim 6, it is preferable that the brushless motor described in any one of claims 1 to 5 is used in a brushless fan motor apparatus including a fan.

  In order to solve the above-mentioned problem, in the invention according to claim 7, a rotor configured to have a rotor magnet, and a plurality of stator coils are arranged so as to face the rotor magnet in the rotation axis direction. In a method for manufacturing a brushless motor, comprising: a stator core; and a connection terminal unit configured to have a connection terminal unit that connects terminal portions of the plurality of stator coils. The connection terminal unit is molded with a resin member. A first step of forming the connection terminal unit, connecting the connection terminal unit and the stator core, placing the stator coil on the stator core, a terminal portion of the stator coil, and the connection terminal unit. A second step of connecting to the connection terminal portion, the connection terminal unit, the plurality of stator coils, and the spacer. A third step of forming a stator assembly by integrally molded the stator core in a resin member, is characterized in that comprises a.

  Thus, according to the seventh aspect of the invention, since the connection terminal unit, the plurality of stator coils, and the stator core are integrally molded with the resin member, the connection terminal unit and the plurality of connection terminals are assembled during the assembly operation of the brushless motor. It is possible to prevent the stator coil and the stator core from being scattered. Thereby, it becomes possible to easily assemble the stator unit including the connection terminal unit, the plurality of stator coils, and the stator core to the motor body.

  Moreover, since the connection terminal unit is formed by molding the connection terminal portion, the shape and position of the connection terminal portion can be fixed by the resin member. This makes it easy to handle the connection terminal unit during the assembly operation of the brushless motor.

  At this time, as described in claim 8, in the third step, the connection terminal unit, the plurality of stator coils, and the stator core are integrally molded with a resin member to form a stator unit. The external mounting stay may be formed integrally with the stator unit by a resin member by molding. Thus, according to the present invention, when the stator unit is formed by integrally molding the connection terminal unit, the plurality of stator coils and the stator core with the resin member, the external mounting stay is simultaneously formed on the stator unit. It is possible to eliminate the need to separately mold the external mounting stay. As a result, the number of manufacturing steps can be reduced as compared with the conventional case, and the increase in the number of parts can be prevented, so that the manufacturing cost can be reduced.

  According to the ninth aspect of the present invention, in the third step, when the external mounting stay is formed near the boundary of the plurality of stator coils in the stator unit, the resin joins at the position where the external mounting stay is formed. The external mounting stay can be formed without doing so. Therefore, it is possible to improve the appearance of the external mounting stay and to secure the strength of the external mounting stay.

  Hereinafter, an embodiment of the present invention will be described with reference to the drawings. It should be noted that members, arrangements, and the like described below do not limit the present invention, and it goes without saying that various modifications can be made in accordance with the spirit of the present invention.

  First, the configuration of a brushless motor according to an embodiment of the present invention will be described.

  The brushless motor 10 according to an embodiment of the present invention is suitably applied to, for example, a brushless fan motor device for cooling a radiator of a passenger car or the like. As illustrated in FIG. The stator unit 30, the circuit unit 40, and the back frame 50 are configured.

  The rotor 20 includes a rotor yoke 22 configured in a disk shape, and an annular rotor magnet 24 is fixed to a flat surface portion 22a of the rotor yoke 22 on the stator unit 30 side. In the rotor magnet 24, N poles and S poles are alternately formed along the circumferential direction (for example, eight poles are formed).

  An annular shaft support portion 22b is formed at the center of the rotor yoke 22, and a rotating shaft 26 is fitted into the shaft support portion 22b. The rotating shaft 26 is rotatably supported by a bearing member 32 provided in a stator unit 30 described later, and a fan (not shown) is fixed to the tip of the rotating shaft 26 by a fixing tool such as a screw. It is like that.

  As shown in FIGS. 3 and 4, the stator unit 30 includes a connection terminal unit 60, a stator coil 70, and a back yoke 80 as a stator core. As will be described in detail later, the stator unit 30 of this example is an integrated unit obtained by further molding a molded connection terminal unit 60, a stator coil 70, and a back yoke 80. It is configured in the shape of

  That is, the configuration of the molded stator unit 30 will be described. On the motor rotation shaft of the stator unit 30, a hole 30a for inserting the rotation shaft 26 is formed. A bearing support portion 30b for supporting the bearing member 32 is formed at two positions spaced apart in the motor rotation axis direction. An outer mounting stay 30c extending in the radial direction is formed at a position near the boundary of the stator coil 70 in the radially outer portion of the stator unit 30.

  Further, a connection terminal unit 60 is disposed on the rotor 20 side of the stator unit 30 so as to face the rotor 20, and in the radially outer portion of the connection terminal unit 60, the rotor magnet 24 and the axial direction are provided. A stator coil 70 is provided so as to face each other. The stator coil 70 of this example is connected in a Y shape by a connection terminal unit 60, and a back yoke 80 is integrally connected to the connection terminal unit 60.

  As shown in FIG. 5, the connection terminal unit 60 of this example is a substantially disk-shaped member in which the connection terminal frame 62 and the resin member are integrated by molding the connection terminal frame 62 (bus bar). . FIG. 5 is a diagram showing a configuration of the connection terminal unit 60 at a stage before being molded into the stator unit 30. As shown in FIG. 5, a hole 60a penetrating in the motor rotation axis direction is formed at the center of the connection terminal unit 60, and the inner annular molded portion 60b formed around the hole 60a includes The connection terminal frame 62 is molded.

  As shown in FIG. 6, the connection terminal frame 62 used in the connection terminal unit 60 includes a U-phase frame 62U, a V-phase frame 62V, a W-phase frame 62W, and a common frame 62C. Each of the U-phase frame 62U, the V-phase frame 62V, the W-phase frame 62W, and the common frame 62C is formed by bending an elongated conductive flat plate member into an arc shape around the motor rotation axis.

  Each of the U-phase frame 62U, the V-phase frame 62V, and the W-phase frame 62W is connected to the terminal portion 72 (see FIGS. 1 and 9) of the stator coil 70 for each of the U-phase, V-phase, and W-phase. A connection terminal 64 for this purpose is formed. As shown in FIG. 7, the connection terminal 64 is formed by bending outward in the radial direction with respect to the arcuate frame main body 65 formed in the frames 62U, 62V, 62W of the respective phases.

  Further, the common frame 62C is formed with a connection terminal 66 for connecting to a terminal portion 74 (see FIGS. 2 and 9) which is a neutral point of the U-phase, V-phase, and W-phase stator coils 70, respectively. Yes. As shown in FIG. 8, the connection terminal 66 is formed radially outward with respect to the arcuate frame main body 67 formed in the common frame 62C. The common frame 62 </ b> C of this example is formed with a wall-like molten resin inflow suppressing portion 68 that is folded back in a U shape between the connection terminal 66 and the frame main body portion 67.

  In this example, the U-shaped folded portion of the molten resin inflow suppressing portion 68 is configured to protrude above the connection terminal 66 in the motor rotation axis direction (the rotor 20 side, hereinafter the same). As will be described later in detail, the molten resin inflow suppressing portion 68 is formed by a mold (not shown) when the connection terminal unit 60, the stator coil 70, and the back yoke 80 are integrally molded to form the stator unit 30. ) Serves as a protective wall for preventing the high pressure of the molten resin flowing in from the gate G from being applied to the connection part 90 between the connection terminal 66 and the terminal part 74 of the stator coil 70.

  As shown in FIG. 5 and FIG. 9, the resin molded portion on the radially outer side of the inner annular molded portion 60 b formed in the connection terminal unit 60 and in which the connection terminals 64 and 66 are located is arranged in the plate thickness direction. A plurality of notch portions 60c are formed therethrough. In this example, by providing the notched portion 60c in the resin molded portion of the connection terminal unit 60 in this way, the connection terminals 64 and 66 protrude from the inner annular molded portion 60b outward in the radial direction, respectively. 66 and the terminal portions 72 and 74 of the stator coil 70 can be connected to each other by spot welding or the like through the notch portion 60c.

  In addition, as shown in FIG. 1, in the portion where the connection terminal 64 is located, the inner annular molded portion 60 b of this example suppresses inflow of a wall-shaped molten resin that protrudes upward in the motor rotation axis direction from the connection terminal 64. A portion 69 is formed. Similarly to the molten resin inflow suppressing portion 68, the molten resin inflow suppressing portion 69 is formed by integrally molding the connection terminal unit 60, the stator coil 70, and the back yoke 80 to form the stator unit 30. It serves as a protective wall for preventing the high pressure of the molten resin flowing in from the gate G (not shown) from being applied to the connection part 90 between the connection terminal 64 and the terminal part 72 of the stator coil 70. .

  As shown in FIGS. 5 and 9, a plurality of stators for fixing the stator coil 70 are fixed to the outer annular molded portion 60 d formed radially outside the inner annular molded portion 60 b of the connection terminal unit 60. A coil fixing portion 60e is formed. Further, a salient pole insertion portion 60f penetrating in the plate thickness direction is formed inside the stator coil fixing portion 60e. In this example, the salient pole 82 of the back yoke 80 is inserted into the salient pole insertion portion 60f. Be able to. Further, an insulating wall 60g is provided between the stator coil fixing portion 60e and the stator coil fixing portion 60e so that adjacent stator coils in the stator coil 70 do not contact each other.

  As shown in FIG. 3, the circuit unit 40 includes a heat sink 42 and a circuit board 44. The heat sink 42 is disposed on the opposite side of the stator unit 30 from the rotor 20, and the circuit board 44 is provided on the opposite side of the heat sink 42 from the stator unit 30. The circuit board 44 is provided with a driver IC 44a and other electronic components, and the driver IC 44a is connected to the connection terminal unit 60 by a wiring member 44b. The circuit unit 40 is covered with a back frame 50 on the side opposite to the stator unit 30.

  Next, the manufacturing method of the brushless motor which consists of the said structure is demonstrated.

  First, the manufacturing method of the stator unit 30 which is a characteristic part of the present invention among the components of the brushless motor 10 will be described. In order to manufacture the stator unit 30, first, the connection terminal unit 60 (sub-ASSY) shown in FIG. 5 is molded using a mold (not shown).

  In order to mold the connection terminal unit 60, the connection terminal frame 62 is concentrically overlapped in this order from the radially inner side in the order of the common frame 62C, the W-phase frame 62W, the V-phase frame 62V, and the U-phase frame 62U. The frame 62 is set in a mold (not shown). In addition, this metal mold | die is comprised so that the connection terminal unit 60 can be shape | molded in a defined shape.

  And after setting the connection terminal unit 60 in a metal mold | die as mentioned above, the molten resin material is filled in a metal mold | die. Subsequently, when the molded product is removed from the mold after the resin material filled in the mold is cooled and solidified, a connection terminal unit 60 having a predetermined shape as shown in FIG. 5 is formed. That is, by molding as described above, a generally disk-shaped connection terminal unit 60 in which the connection terminal frame 62 (bus bar) is integrated with the resin member is formed.

  At this time, as shown in FIGS. 1, 2 and 5, the connection terminals 64 and 66 protrude from the inner annular molded portion 60b into the notch 60c, and from the connection terminal 64 to the inner annular molded portion 60b. Also, a wall-shaped molten resin inflow suppressing portion 69 protruding upward in the motor rotation axis direction is formed. Further, the U-shaped folded portion of the molten resin inflow suppressing portion 68 formed on the common frame 62C is disposed at the upper portion of the inner annular molded portion 60b and protrudes upward in the motor rotation axis direction from the connection terminal 66. Become.

  9, the salient poles 82 formed on the back yoke 80 are inserted into the salient pole insertion portions 60f of the connection terminal unit 60, and the back yoke 80 is connected to the connection terminal unit 60 from the back side of the connection terminal unit 60. 60. Subsequently, the stator coils 70 wound in a predetermined shape are respectively fixed to the stator coil fixing portions 60 e of the connection terminal units 60. The back yoke 80 may be connected to the connection terminal unit 60 after the stator coil 70 wound in a predetermined shape is fixed to the stator coil fixing portion 60e of the connection terminal unit 60, respectively. In this example, the stator coil 70 is placed on the back yoke 80 via the stator coil fixing portion 60 of the connection terminal unit 60.

  Next, as shown in FIG. 9, the terminal portions 72 and 74 of the stator coil 70 are connected to the connection terminals 64 and 66, respectively. At this time, the terminal portions 72 and 74 of the stator coil 70 are connected to the connection terminals 64 and 66, for example, by spot welding. Note that the connection terminals 64 and 66 may be provided with claws, and the connection terminals 64 and 66 and the terminal portions 72 and 74 of the stator coil 70 may be connected by caulking the claws. Alternatively, the terminal portions 72 and 74 of the stator coil 70 may be spot welded to the connection terminals 64 and 66 after the connection terminals 64 and 66 are crimped.

  Subsequently, in a state where the stator coil 70 is fixed and connected to the connection terminal unit 60 as described above, and the back yoke 80 is connected to the connection terminal unit 60, these are set in a mold (not shown). The mold is configured so that the stator unit 30 can be formed into a predetermined shape, and the gate G leading to the cavity in the mold is a connection terminal as shown in FIG. The unit 60 is disposed in a portion radially inward of the inner annular molded portion 60b (for example, at the center position of the hole 60a in the same plane as the connection terminal unit 60).

  Then, the molten resin material is filled into the cavity of the mold through the gate G. At this time, as described above, the connection terminal unit 60 set in the mold has the wall-shaped molten resin inflow suppression portions 68 and 69 between the gate G of the mold and the connection terminals 64 and 66. Each is formed.

  Therefore, even if high-pressure molten resin flows into the cavity from the gate G of the mold, this high-pressure molten resin suppresses the inflow of the molten resin in the shape of a wall as shown by the broken line A in FIG. After hitting the portion 68, it flows by the side of the molten resin inflow suppressing portion 68 and flows from the side surface side of the connection terminal 64 to the connection portion 90 side, so that a high-pressure molten resin enters the connection portion as in the prior art. Compared with the method of flowing directly, the pressure of the molten resin flowing in the connection part 90 can be kept low.

  Similarly, even when a high-pressure molten resin flows into the cavity from the gate G of the mold, the molten resin inflow suppressing portion 69 is not subjected to contact with the wall-shaped molten resin inflow suppressing portion 69. Since it flows along the side of the molten resin inflow suppressing portion 69 and flows from the side surface side of the connection terminal 66 to the connection portion 90 side, the high pressure molten resin flows directly into the connection portion as in the prior art. In comparison, the pressure of the molten resin flowing through the connection part 90 can be kept low.

  That is, in this example, the molten resin inflow suppressing portions 68 and 69 serve as a protective wall so that the high pressure of the molten resin is not directly applied to the connection portion 90. Therefore, the connection terminal unit 60, the stator coil 70, and the back yoke 80 are integrally molded to form the stator unit 30 without the connection portion 90 being cut or the connection terminals 64 and 66 being bent. be able to.

  When the molded product is removed from the mold after the resin material filled in the mold is cooled and solidified, a stator unit 30 having a predetermined shape as shown in FIG. 2 is formed. That is, as described above, the connection terminal unit 60, the stator coil 70, and the back yoke 80 can be molded to form the stator unit 30 having a predetermined shape.

  Next, as shown in FIG. 3, the rotor 20, the circuit unit 40, and the back frame 50 are sequentially assembled to the stator unit 30 formed as described above, thereby completing the brushless motor 10 of this example.

  In this way, in this example, the stator unit 30 can be formed as a single unit by molding the connection terminal unit 60, the plurality of stator coils 70, and the back yoke 80. The connection terminal unit 60, the plurality of stator coils 70, and the back yoke 80 can be prevented from being scattered. Thereby, the stator unit 30 can be easily assembled to the motor body.

  In this example, when the connection terminal unit 60, the plurality of stator coils 70, and the back yoke 80 are integrally molded with a resin member to form the stator unit 30, the external mounting stay 30c is simultaneously attached to the stator unit 30. Since it is formed, it is not necessary to separately mold the external mounting stay 30c. As a result, the number of manufacturing steps can be reduced as compared with the conventional case, and the increase in the number of parts can be prevented, so that the manufacturing cost can be reduced.

  Further, in this example, the external mounting stay 30c is formed in the vicinity of the boundary between the plurality of stator coils 70 in the stator unit 30, so that the external mounting stay is not joined at the position where the external mounting stay 30c is formed. 30c can be molded. Therefore, the external appearance of the external mounting stay 30c can be improved, and the strength of the external mounting stay 30c can be ensured.

  In this example, since the connection terminal unit 60 is formed by molding the connection terminal frame 62, the shape and position of the connection terminal frame 62 can be fixed by the resin member. Thereby, the handling of the connection terminal unit 60 can be facilitated during the assembly operation of the brushless motor 10.

  In addition, according to this example, when the stator unit 30 is manufactured, the wall-shaped molten resin inflow suppressing portions 68 and 69 are provided in the vicinity of the connection portion 90 of the stator coil 70 and the connection terminal unit 60. Thus, the pressure of the molten resin flowing through the connection portion 90 can be kept low as compared with the method in which the high-pressure molten resin flows directly into the connection portion 90 as described above. Therefore, it is possible to prevent the connection portion 90 between the stator coil 70 and the connection terminal unit 60 from being cut or the connection terminals 64 and 66 from being bent, and the connection portion 90 can be reliably molded.

  The molten resin inflow suppressing portion 68 is formed in advance on the common frame 62C, and the molten resin inflow suppressing portion 69 is formed at the stage of molding the connection terminal unit 60. Therefore, it is not necessary to use another member serving as a protective wall when molding the connection terminal unit 60, so that it is possible to prevent an increase in manufacturing man-hours and an increase in manufacturing cost due to the addition of another member.

  Further, in the molding process of the connection terminal unit 60, which is a stage before the stator unit 30 is molded, the stator coil 70 is formed by a very simple method of integrally providing the molten resin inflow suppressing portions 68 and 69 in the connection terminal unit 60. And the pressure of the molten resin added to the connection part 90 of the connection terminal unit 60 can be reduced reliably. Thereby, the yield of the brushless motor 10 can be significantly improved as compared with the conventional method in which the high-pressure molten resin directly hits the connection portion 90 of the stator coil 70 and the connection terminal unit 60.

  The embodiment of the present invention can be modified as follows.

  (1) In the above embodiment, the connection terminal unit 60, the plurality of stator coils 70, and the back yoke 80 have been described as being integrally molded with a resin member. However, the present invention is not limited to this. In addition, the plurality of stator coils 70 and the stator core 80 may be configured to be integrally molded with a resin member.

  (2) Moreover, in the said embodiment, as a means for suppressing that molten resin flows in into the connection terminals 64 and 66 at the time of molding of the connection terminal unit 60, two different types of molten resin inflow suppression parts 68 and fusion | melting Although the resin inflow suppressing portion 69 is provided, in addition, as a means for suppressing the molten resin from flowing into the connection terminals 66 and 68, any one of the two different types of molten resin connection terminals 68 and 69 can be used. You may make it unify to such a structure.

  (3) In the above-described embodiment, the molten resin inflow suppressing portions 68 and 69 have been described so as to protrude upward in the motor rotation axis direction with respect to the connection terminals 64 and 66. The terminals 64 and 66 may be configured to protrude outward in the motor radial direction. Moreover, you may make it protrude on both sides of a motor rotating shaft direction upper side and a motor radial direction outer side with respect to the connection terminals 64 and 66. FIG. Furthermore, you may form in a flange shape so that it may extend in the direction which cross | intersects the longitudinal direction of the connection terminals 64 and 66. FIG.

  Next, technical ideas derived from the above embodiments other than the invention described in the claims will be described. That is, the first technical idea is that a connection portion between the connection terminal portion of the connection terminal unit and the terminal portion of the stator coil is integrated with a resin member by molding using a mold, and the connection terminal unit is connected to the connection terminal unit. 5. The brushless motor according to claim 1, wherein a wall-shaped molten resin inflow suppressing portion is formed in the vicinity of the connection portion to suppress a flow of the molten resin at the time of molding. It is.

  Further, the second technical idea is that in the first step, the flow of the molten resin at the time of molding is suppressed in the vicinity of the connection portion between the connection terminal portion of the connection terminal unit and the terminal portion of the stator coil. Forming a wall-shaped molten resin inflow suppressing portion, and in the third step, at least the connection portion and the molten resin inflow suppressing portion are set in a mold for molding, and from the gate of the mold The molten resin is injected and filled in the mold, and the molten resin filled in the mold is cooled and solidified to integrate at least the connection portion and the resin member. 6. A method for manufacturing a brushless motor according to claim 6 or claim 7.

  As described above, when the wall-shaped molten resin inflow suppressing portion is formed in the vicinity of the connection portion between the connection terminal portion of the connection terminal unit and the terminal portion of the stator coil, when the mold is formed, Even if a high-pressure molten resin flows into the wall, the flow of the high-pressure molten resin can be suppressed by the wall-shaped molten resin inflow suppressing portion. Therefore, the pressure of the molten resin flowing through the connecting portion can be reduced as compared with the conventional method in which high-pressure molten resin flows directly into the connecting portion. Thereby, it can prevent that the connection part of a stator coil and a connection terminal unit is cut | disconnected, or a connection terminal bends, and it can mold a connection part reliably.

  In addition, the wall-shaped molten resin inflow suppressing portion can be formed at the stage of molding the connection terminal unit, for example, or can be formed in advance on the connection terminal portion of the connection terminal unit. It is possible to eliminate the need for a separate member that serves as a protective wall when the unit is molded. Thereby, the increase in manufacturing man-hours can be prevented, and the increase in manufacturing cost due to the addition of another member can also be prevented.

  Further, in the molding process of the connection terminal unit, which is the stage before molding the stator, a very simple method of integrally providing a molten resin inflow suppression part in the connection terminal unit is provided on the connection part of the stator coil and the connection terminal unit. The pressure of the molten resin applied can be reliably reduced. As a result, the yield of the brushless motor can be greatly improved as compared with the conventional technique in which a high-pressure molten resin directly hits the connection portion between the stator coil and the connection terminal unit.

  Further, according to a third technical idea, the molten resin inflow suppressing portion is formed between a portion where the gate of the mold is located and the connection portion. 4 is a brushless motor.

  Furthermore, the fourth technical idea is that, in the first step, the molten resin inflow suppressing portion is formed between a portion where the gate of the mold is located and the connecting portion. 6. A method for manufacturing a brushless motor according to claim 6 or claim 7.

  As described above, when the molten resin inflow suppressing portion is formed between the portion where the gate of the mold is located and the connecting portion, the flow of the molten resin flowing from the gate is surely suppressed by the wall-shaped molten resin inflow suppressing portion. This is preferable.

  The fifth technical idea is that the molten resin inflow suppressing portion is formed between the rotating shaft of the rotor and the connecting portion. It is a brushless motor.

  Furthermore, the sixth technical idea is that, in the first step, the molten resin inflow suppressing portion is formed between the rotating shaft of the rotor and the connecting portion. 7 is a method of manufacturing a brushless motor according to item 7.

  In this way, when the molten resin inflow suppressing portion is formed between the rotor rotating shaft and the wire connecting portion, the molten resin inflow into the portion having a relatively large space between the rotor rotating shaft and the wire connecting portion. Since the suppression part can be formed, it is possible to prevent an increase in the size of the brushless motor by providing the wall-shaped molten resin inflow suppression part, which is preferable.

  Further, a seventh technical idea is that the connection terminal unit is configured to have a resin molding portion that covers at least a part of the connection terminal portion, and the molten resin inflow suppression portion is formed in the resin molding portion. The brushless motor according to claim 1, wherein the brushless motor is provided.

  Furthermore, an eighth technical idea is characterized in that, in the first step, the molten resin inflow suppressing portion is formed in a resin molded portion that covers at least a part of the connection terminal portion of the connection terminal unit. A method of manufacturing a brushless motor according to claim 6 or 7.

  The ninth technical idea is the brushless motor according to any one of claims 1 to 4, wherein the molten resin inflow suppressing portion is formed in a part of the connection terminal portion.

  The tenth technical idea is that the molten resin inflow suppressing portion is formed in a part of the connection terminal portion in the first step. It is a manufacturing method of a motor.

  Thus, the wall-shaped molten resin inflow suppressing portion may be formed in a resin molding portion that covers at least a part of the connection terminal portion of the connection terminal unit, or formed in a part of the connection terminal portion. May be.

It is sectional drawing which shows the structure of the connection part of the stator coil and connection terminal unit which concern on one Embodiment of this invention. It is sectional drawing which shows the structure of the connection part of the stator coil and connection terminal unit which concern on one Embodiment of this invention. It is a figure which shows the structure of the brushless motor which concerns on one Embodiment of this invention. It is a figure which shows the structure of the stator which concerns on one Embodiment of this invention. It is a figure which shows the structure of the connection terminal unit which concerns on one Embodiment of this invention. It is a figure which shows the structure of the connection terminal frame which concerns on one Embodiment of this invention. It is explanatory drawing which shows the cross-sectional structure of the connection terminal which concerns on one Embodiment of this invention. It is explanatory drawing which shows the cross-sectional structure of the connection terminal which concerns on one Embodiment of this invention. It is a figure which shows the state which fixed the stator coil to the connection terminal unit which concerns on one Embodiment of this invention. It is explanatory drawing which shows a mode that molten resin flows into the connection part of the stator coil which concerns on one Embodiment of this invention, and a connection terminal unit.

Explanation of symbols

DESCRIPTION OF SYMBOLS 10 ... Brushless motor, 20 ... Rotor, 22 ... Rotor yoke, 22a ... Planar part, 22b ... Shaft support part, 24 ... Rotor magnet, 26 ... Rotating shaft, 30 ... Stator unit, 30a ... Hole part, 30b ... Bearing support part, 30c ... External mounting stay, 32 ... Bearing member, 40 ... Circuit unit, 42 ... Heat sink, 44 ... Circuit board, 44a ... Driver IC, 44b ... Wiring member, 50 ... Back frame, 60 ... Connection terminal unit, 60a ... Hole , 60b ... inner annular molded part (resin molded part), 60c ... notch, 60d ... outer annular molded part, 60e ... stator coil fixing part, 60f ... salient pole insertion part, 60g ... insulating wall, 62 ... connection terminal frame ( Connection terminal section), 62C ... common frame, 62U ... U-phase frame, 62V ... V-phase frame, 62W ... W-phase frame 64, 66 ... connection terminal, 65, 67 ... frame main body part, 68, 69 ... molten resin inflow suppressing part, 70 ... stator coil, 72, 74 ... terminal part, 80 ... back yoke (stator core), 82 ... salient pole, 90 ... Connection part, G ... Gate

Claims (9)

A rotor configured with a rotor magnet;
A stator core in which a plurality of stator coils are arranged to face the rotor magnet in the rotation axis direction;
In a brushless motor comprising a connection terminal unit configured to have a connection terminal portion for connecting terminal portions of the plurality of stator coils,
The brushless motor, wherein the plurality of stator coils and the stator core are integrally molded with a resin member. A rotor configured with a rotor magnet;
A stator core in which a plurality of stator coils are arranged to face the rotor magnet in the rotation axis direction;
In a brushless motor comprising a connection terminal unit configured to have a connection terminal portion for connecting terminal portions of the plurality of stator coils,
The brushless motor, wherein the connection terminal unit, the plurality of stator coils, and the stator core are integrally molded with a resin member. A rotor configured with a rotor magnet;
A stator core in which a plurality of stator coils are arranged to face the rotor magnet in the rotation axis direction;
In a brushless motor comprising a connection terminal unit configured to have a connection terminal portion for connecting terminal portions of the plurality of stator coils,
The connection terminal unit, the plurality of stator coils, and the stator core are integrally molded with a resin member to form a stator unit, and the molding unit forms an external mounting stay with the resin member. A brushless motor characterized by being formed.   The brushless motor according to claim 3, wherein the external mounting stay is formed at a position near a boundary between the plurality of stator coils in the stator unit.   5. The connection terminal unit according to claim 1, wherein the connection terminal part and the resin member are integrally formed by molding the connection terminal part. A brushless motor according to claim 1. A brushless motor,
In a brushless fan motor device comprising a fan rotated by the brushless motor,
A brushless fan motor device using the brushless motor according to any one of claims 1 to 5 as the brushless motor. A rotor configured to have a rotor magnet, a stator core in which a plurality of stator coils are arranged so as to face the rotor magnet in the rotation axis direction, and a connection terminal portion that connects terminal portions of the plurality of stator coils. In a manufacturing method of a brushless motor comprising a connection terminal unit configured to have,
A first step of forming the connection terminal unit by molding the connection terminal portion with a resin member;
A second step of connecting the connection terminal unit and the stator core, placing the stator coil on the stator core, and connecting the terminal portion of the stator coil and the connection terminal portion of the connection terminal unit; ,
And a third step of forming the stator unit by integrally molding the connection terminal unit, the plurality of stator coils, and the stator core with a resin member.   8. The method of manufacturing a brushless motor according to claim 7, wherein, in the third step, an external mounting stay is integrally formed with a resin member on the stator unit by the molding.   9. The method of manufacturing a brushless motor according to claim 8, wherein, in the third step, the external mounting stay is formed at a position near a boundary between the plurality of stator coils in the stator unit.

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