JP2014086253A - Power supply module - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide an inexpensive power supply module supplying power to a load, sealed by an insulation body, capable of absorbing a deviation from a proper fitting position due to an assembling error of a first connector terminal of the load and a second connector terminal of the power supply module, and directly and electrically connecting the load and the power supply module through the second connector terminal.SOLUTION: In a power supply module 81 supplying power to a load and sealed by an insulation body 1a, a through-hole 8a in which a first connector terminal T1 of the load is introduced is formed on the insulation body 1a.

Description

  The present invention relates to a power supply module sealed with an insulator for supplying power to a load.

  A power supply module sealed with an insulator for supplying power to a load is disclosed in, for example, Japanese Patent Application Publication No. 2004-524701 (Patent Document 1) and Japanese Patent Application Laid-Open No. 2011-77280 (Patent Document 2). .

  FIG. 14 is a diagram illustrating an example of a usage form of a conventional power supply module. A cover 11b that covers a housing 11a of the drive motor 10 for a power supply module (inverter module) 20 that supplies power to an electromechanical integrated electric compressor. It is the figure which showed typically the assembly | attachment structure to.

  FIG. 15 is an enlarged cross-sectional view of the second connector terminal 50a of the connector 50 shown in FIG. Note that FIG. 15 is reversed in the vertical direction from FIG.

  In recent years, an electric compressor in a vehicle air-conditioning system adopts a so-called electro-mechanical integrated structure in which a compressor drive motor and a power supply module that supplies electric power to the drive motor are housed in a set of housings for miniaturization. It is being done.

  As shown in FIG. 14, in an electromechanical integrated electric compressor, a three-phase drive motor 10 for driving the compressor is hermetically housed in a housing 11a in which a refrigerant circulates. For this reason, the power supply to the drive motor 10 is performed via the three airtightly sealed first connector terminals T1 penetrating the housing 11a. As shown in the drawing, a cylindrical male type is usually used for the first connector terminal T1.

  On the other hand, the power supply module 20 that supplies power to the load drive motor 10 is fixed to the heat dissipation member 30 with screws and mounted on the printed circuit board 40, and attached to the cover 11b. The power supply module 20 is sealed with an insulator (mold resin) by transfer molding, and a lead frame including output terminals protruding from the mold resin is joined to the wiring pattern of the printed circuit board 40 by soldering. . A connector 50 having a female second connector terminal 50a fitted to the first connector terminal T1 is mounted on the printed circuit board 40, and the output lead L1 of the power supply module 20 and the second connector terminal 50a of the connector 50 are mounted. The lead L <b> 2 connected to is electrically connected with the wiring pattern of the printed circuit board 40.

  Then, as shown in FIG. 14, the cover 11b to which the printed circuit board 40 is attached is put on the housing 11a of the drive motor 10, whereby the first connector terminal T1 and the second connector terminal 50a are fitted, and the power supply module 20 And the drive motor 10 are electrically connected. At the same time, the heat dissipation member 30 contacts the housing 11a.

  As shown in FIGS. 14 and 15, the second connector terminal 50a of the connector 50 fitted to the first connector terminal T1 of the load is accommodated in an insulator (mold resin) 50b by transfer molding. Further, in the assembly structure shown in FIG. 14, the central axis of the first connector terminal T1 and the central axis of the second connector terminal 50a may deviate from an appropriate fitting position due to an assembly error or the like. For this reason, as shown in FIG. 15, a guide tape 50c having a tapered shape for facilitating the insertion of the first connector terminal T1 is provided around the insertion hole 50d on the lower surface of the insulator 50b of the connector 50. . Then, the printed circuit board 40 is entirely displaced along the guide 50c, thereby facilitating the fitting of the first connector terminal T1 and the second connector terminal 50a.

JP-T-2004-524701 JP 2011-77280 A

  In the connection structure of the power supply module 20 and the drive motor 10 shown in FIG. 14, there are many solder connection points in the power supply line from the power supply module 20 to the load drive motor 10. These solder connection points have high impedance and may become a heat generating part when a large current is applied. In addition, the printed circuit board 40 requires a mounting space for the power supply module 20 and the connector 50 and a wiring space for connecting them, which increases the size. As one method for solving these problems, it is considered that the load and the power supply module are directly electrically connected only by the second connector terminal fitted to the first connector terminal T1 of the load without using the printed circuit board 40. It is done. However, even in this case, the displacement from the proper fitting position due to the assembly error of the first connector terminal T1 and the second connector terminal, etc., like the entire displacement of the guide 50c and the printed circuit board 40 described in FIG. A simple and inexpensive mechanism to absorb is needed.

  Accordingly, the present invention provides a power supply module sealed with an insulator that supplies power to a load, and the proper fitting caused by an assembly error between the first connector terminal of the load and the second connector terminal of the power supply module. An object of the invention is to provide an inexpensive power supply module that can absorb the deviation from the joint position and that can directly electrically connect the load and the power supply module via the second connector terminal. Yes.

  The power supply module according to the present invention is a power supply module sealed with an insulator that supplies power to a load, and a through hole for introducing a first connector terminal of the load is formed in the insulator. It is characterized by becoming.

  In the power supply module, a through hole for introducing the first connector terminal of the load is formed in an insulator sealing the power supply module. The through hole can have a function of roughly positioning the first connector terminal of the load, and by disposing the second connector terminal fitted to the first connector terminal above or below the through hole, both ends are provided. The child can be easily fitted. Further, in the power supply module in which the through hole is formed, since the insulator around the through hole covers the second connector terminal, the terminal cover of the second connector terminal can be eliminated. In addition, since the said through-hole can be formed previously at the time of shaping | molding the insulator of the said power supply module, it does not raise a special cost.

  The insulator that seals the power supply module may be, for example, a widely used mold resin by transfer molding. However, the power supply module according to the present invention is not limited to this, and may be a power supply module using a ceramic package as a sealing insulator, or a power supply module sealed with resin by potting.

  It is preferable that a tapered guide for facilitating introduction of the first connector terminal is provided at the introduction end of the first connector terminal in the through hole. In particular, when the terminal cover of the second connector terminal is eliminated, the tapered guide is required. Note that the guide can be formed in advance when the insulator of the power supply module is molded, so that the cost does not increase.

  In the power supply module, it is preferable that the second connector terminal fitted to the first connector terminal introduced into the through hole is joined to the power supply frame exposed from the insulator.

  In other words, in the power supply module, the second connector terminal fitted to the first connector terminal of the load seals the power supply module without going through the power supply line such as a lead wire or a printed board. It is directly joined to the power supply frame exposed from the body. Since the second connector terminal is retrofitted to the main body of the power supply module sealed with an insulator and installed outside the insulator, the degree of freedom in selecting the shape according to the first connector terminal of the load is high.

  Accordingly, the power supply module is a power supply module sealed with an insulator that supplies power to the load, and can be electrically connected to an arbitrary load without using a lead wire or a printed board. It can be a power supply module.

  In the power supply module, the second connector terminal joined to the power supply frame exposed from the insulator includes a joint part joined to the frame, a fitting part fitted to the first connector terminal of the load, and an elastic member. It is preferable that the arm portion is deformable and connects the joint portion and the fitting portion.

  By providing an elastically deformable arm portion between the joint portion and the fitting portion, even if there is a positional deviation or an angular deviation at the time of fitting with respect to the first connector terminal, the elasticity of the arm portion of the second connector terminal is concerned. Can be absorbed by deformation. Therefore, even if there is a positional deviation or an angular deviation during fitting, unscheduled stress is not generated in the joint portion and the fitting portion, and stable electrical connection can be maintained.

  In order to manufacture the second connector terminal having the above configuration at low cost, it is preferable that the joint portion, the fitting portion, and the arm portion are integrally formed by bending.

  As described above, since the second connector terminal is retrofitted to the power supply module sealed with the insulator and installed outside the insulator, the degree of freedom in shape selection is high. Therefore, the first connector terminal of the load is a male terminal, and the second connector terminal joined to the power supply frame has a generally complicated shape with respect to the male first connector terminal. A female terminal may be used.

  When the second connector terminal is a female terminal, the fitting portion of the second connector terminal is formed with the above-described guide taper shape of the through hole for introducing the male first connector terminal. And placed on the opposite side of the introduction end.

  Further, when the second connector terminal is a female terminal, for example, the fitting portion covers the contact piece portion including four contact pieces having spring properties that are annularly connected at one end and the contact piece portion. It is possible to adopt a structure formed by a cylindrical part formed separately. According to this, the tangent line (contact beam) with a male 1st connector terminal can be made into 4 lines, and the energization current which can be used can be raised compared with the case where a contact beam is 2 lines.

  In addition, when the second connector terminal is a female terminal, when the male first connector terminal is inserted into the second connector terminal, it is caught by a part of the insulator to limit the displacement of the fitting portion. The hook part is preferably formed integrally.

  When pulling out the male first connector terminal, the predetermined portion of the insulator sealing the power supply module may be a part that restricts the displacement of the fitting portion that fits into the first connector terminal. it can. On the other hand, when the first connector terminal is inserted, a displacement in the opposite direction to that at the time of withdrawal is generated in the fitting portion. Therefore, in order to prevent excessive stress from being generated in the fitting portion, the arm portion, and the joint portion when the first connector terminal is inserted, it is preferable to provide the hook portion by integral molding.

  Further, when the second connector terminal is a female terminal, a tapered guide that facilitates the insertion of the male first connector terminal into the insertion end of the first connector terminal of the load in the fitting portion. Is preferably provided.

  In the power supply module, the second connector terminal is preferably joined to the frame exposed from the insulator by resistance welding having a high joint strength in a short time.

  When joining the second connector terminal to the frame by resistance welding, for example, a hole for inserting one electrode of resistance welding, the surface opposite to the exposed surface of the frame to which the second connector terminal is joined The exposed welding hole is formed in an insulator. According to this, the exposure from the insulator of the power supply frame for joining the second connector terminals can be minimized.

  In the power supply module, the power supply frame may protrude from the insulator and be exposed. According to this, it becomes easy to join the second connector terminal to the frame.

  As described above, the power supply module is a power supply module sealed with an insulator for supplying power to the load, and an assembly error between the first connector terminal of the load and the second connector terminal of the power supply module. An inexpensive power supply module that can absorb a deviation from an appropriate fitting position caused by, etc., and can directly electrically connect a load and the power supply module via the second connector terminal. can do.

  Therefore, in the power supply module, for example, the load is a drive motor of an electric compressor mounted on an automobile and the power supply module is an inverter module that supplies power to the drive motor. Suitable for electric compressors.

  By using the power supply module, it is possible to absorb a shift from an appropriate fitting position due to an assembly error or the like and stably connect the first connector terminal of the load and the second connector terminal of the power supply module. Can do. Furthermore, since no lead wire or printed circuit board is interposed in the power supply line from the power supply module, the solder connection point of the power supply line via the printed circuit board and the connector, which is a problem in the conventional power supply module, can be eliminated. At the same time, the size can be greatly reduced.

It is a figure which shows an example of the usage pattern of the electric power supply module which concerns on this invention, and is about the electric power supply module 80 which supplies electric power to the electromechanical-integrated type electric compressor, and the assembly structure to the cover 11d which covers the housing 11c of the drive motor 10 FIG. FIG. 2 is a diagram illustrating a more specific configuration example of the power supply module 80 illustrated in FIG. 1, in which (a) is a perspective view of the power supply module 81, and (b) is a diagram viewed from above (a). FIG. 6 is an enlarged view of the periphery of the through hole 8a of the power supply module 81. It is a perspective view of the main body Hh before joining 2nd connector terminal T2j. In the figure which expanded and showed 2nd connector terminal T2j, (a), (b) is the perspective view of the whole 2nd connector terminal T2j seen from another angle, respectively (c)-(f) FIG. 4 is a diagram illustrating components of the fitting parts Ka of (a) and (b) disassembled. (A) is the figure which expanded and showed the insertion state of 1st connector terminal T1 to the through-hole 8a. (B) is the figure which removed the insulator 1a of (a), and is the figure which showed the assembly | attachment relationship of the flame | frame of the electric power supply module 81, 2nd connector terminal T2j, and 1st connector terminal T1. FIGS. 9A and 9B are views showing a modification of the power supply module 81 shown in FIG. 2, and FIGS. 7A and 7B are perspective views of the power supply module 82 as viewed from above and below, respectively. FIG. 7 is a diagram viewed from above in FIG. 6A, and is an enlarged view of the periphery of the through hole 8 b of the power supply module 82. It is a figure which shows the main body Hi of the electric power supply module 82 before joining 2nd connector terminal T2k, (a) and (b) are the perspective views which looked at the main body Hi from the upper direction and the downward direction, respectively. It is the perspective view which expanded and showed 2nd connector terminal T2k used with the electric power supply module 82 of FIG. (A)-(c) is the figure which showed the manufacturing process of 2nd connector terminal T2k of FIG. (A)-(c) is the figure which showed the manufacturing process of 2nd connector terminal T2k of FIG. FIG. 7 is a view showing a modification of the power supply module 82 shown in FIG. 6, and is a perspective view of the periphery of the second connector terminal T <b> 2 l of the power supply module 83 as seen from below as in FIG. It is the perspective view which expanded and showed 2nd connector terminal T21 used by the power supply module 83 of FIG. It is a figure which shows an example of the usage pattern of the conventional electric power supply module, and about the electric power supply module 20 which supplies electric power to an electromechanical-integrated electric compressor, the assembly structure to the cover 11b which covers the housing 11a of the drive motor 10 is typically shown FIG. It is sectional drawing which expanded and showed the surroundings of the 2nd connector terminal 50a of the connector 50 in FIG.

  A power supply module according to the present invention is a power supply module sealed with an insulator that supplies power to a load, and the through hole through which the first connector terminal of the load is introduced is formed in the insulator. Supply module.

  Hereinafter, embodiments of a power supply module according to the present invention will be described with reference to the drawings.

  FIG. 1 is a diagram showing an example of a usage form of a power supply module according to the present invention. A power supply module (inverter module) 80 that supplies power to an electric compressor integrated with an electric machine is placed on a housing 11 c of a drive motor 10. It is the figure which showed typically the assembly | attachment structure to the cover 11d. In the structure of FIG. 1, the same parts as those shown in FIG.

  As described with reference to FIG. 14, in the electromechanical integrated electric compressor of FIG. 1, the three-phase drive motor 10 for driving the compressor is sealed and accommodated in the housing 11c in which the refrigerant circulates. For this reason, power is supplied to the drive motor 10 through the three first connector terminals T1 that are hermetically sealed and penetrate the housing 11c. As shown in the drawing, a cylindrical male type is usually used for the first connector terminal T1.

  On the other hand, the power supply module 80 shown in FIG. 1 differs from the conventional power supply module 20 shown in FIG. 14 in that the through hole 8 for introducing the first connector terminal T1 of the load seals the power supply module 80. Is formed on the insulator. Further, the second connector terminal T2 fitted to the first connector terminal T1 of the load is joined to a power supply frame exposed from the insulator, as will be described in detail later. Then, by covering the housing 11c of the drive motor 10 with the cover 11d to which the power supply module 80 is attached, the first connector terminal T1 and the second connector terminal T2 are fitted, and the power supply module 80 and the load drive motor 10 are fitted. Are electrically connected. At the same time, the heat dissipating member 31 fixed to the power supply module 80 contacts the housing 11c.

  In the structure shown in FIG. 14, the central axis of the first connector terminal T1 and the central axis of the second connector terminal 50a may be displaced from the proper fitting position due to an assembly error or the like. For this reason, as shown in FIG. 15, a guide tape 50c having a tapered shape for facilitating the insertion of the first connector terminal T1 is provided around the insertion hole 50d on the lower surface of the insulator 50b of the connector 50. .

  Further, in the conventional power supply module 20 shown in FIG. 14, the lead frame including the output terminals protruding from the mold resin is joined to the wiring pattern of the printed circuit board 40 by soldering. Then, the connector 50 having the female second connector terminal 50a fitted to the first connector terminal T1 is mounted on the printed circuit board 40 together with the power supply module 20, and the cover 11b is put on the housing 11a to supply power. The module 20 and the drive motor 10 were electrically connected. For this reason, in the structure using the conventional power supply module 20 shown in FIG. 14, there are many solder connection points on the power supply line from the power supply module 20 to the drive motor 10 of the load. The point has high impedance and may become a heat generating part when a large current is applied. In addition, the printed circuit board 40 requires a space for mounting the power supply module 20 and the connector 50 and a wiring space for connecting them, resulting in a problem that the printed circuit board 40 becomes large.

  On the other hand, in the power supply module 80 shown in FIG. 1, the through hole 8 for introducing the first connector terminal T1 of the load is formed in an insulator that seals the power supply module 80. The through hole 8 can have a function of roughly positioning the first connector terminal T1 of the load, and the second connector terminal T2 to be fitted to the first connector terminal T1 is disposed above the through hole 8. Thus, the fitting of both terminals can be facilitated. Further, in the power supply module 80 in which the through hole 8 is formed, since the insulator around the through hole 8 covers the second connector terminal T2, the terminal cover of the second connector terminal T2 can be eliminated. . Note that the through hole 8 can be formed in advance when the insulator of the power supply module 80 is formed, so that the cost does not increase specially.

  Further, in the power supply module 80 shown in FIG. 1, the second connector terminal T2 fitted to the first connector terminal T1 of the load seals the power supply module 80 without passing through a power supply line such as a printed board. It is directly joined to the power supply frame exposed from the insulating body.

  Therefore, if the power supply module 80 shown in FIG. 1 is used, unlike the structure shown in FIG. 14, the power supply module 80 and the drive motor 10 can be electrically connected without using a lead wire or a printed board. For this reason, the solder connection point of the power supply line in the printed circuit board 40, which was a problem in the structure using the conventional power supply module 20 shown in FIG. 14, can be eliminated. The printed board 41 is also used in the structure of FIG. 1, but this printed board 41 is a small one in which power supply wiring, communication wiring, and the like to the power supply module 80 are formed. Further, since the second connector terminal T2 in the power supply module 80 of FIG. 1 is retrofitted to the main body of the power supply module 80 sealed with an insulator and installed outside the insulator, the first connector terminal T1 of the load There is a high degree of freedom in selecting the shape to match.

  As described above, the power supply module 80 shown in FIG. 1 is a power supply module sealed with an insulator that supplies power to the load, and includes the first connector terminal T1 of the load and the first power supply module. 2 It is possible to absorb the deviation from the proper fitting position due to the assembly error of the connector terminal T2, and further, the load and the power supply module can be directly electrically connected via the second connector terminal T2. An inexpensive power supply module can be obtained.

  Next, the structure of the power supply module according to the present invention will be described in more detail.

  2 to 5 are diagrams showing more specific configuration examples of the power supply module 80 shown in FIG. 1, and are diagrams showing the power supply module 81 and its components.

  FIG. 2A is a perspective view of the power supply module 81, and FIG. 2B is a diagram viewed from above (a), and is an enlarged view of the periphery of the through hole 8a of the power supply module 81. It is. Note that the perspective view of the power supply module 81 shown in FIG. 2 corresponds to a view seen from the lower direction of FIG. 1 (the first connector terminal T1 side).

  FIG. 3 is a perspective view of the main body Hh before joining the second connector terminal T2j.

  FIG. 4 is an enlarged view of the second connector terminal T2j, and (a) and (b) are perspective views of the entire second connector terminal T2j viewed from different angles, respectively. (F) is the figure which decomposed | disassembled the fitting part Ka of (a) and (b), respectively, and showed the component.

  FIG. 5 is a diagram showing a fitting state of the first connector terminal T1 and the second connector terminal T2j. FIG. 5A is an enlarged view showing the insertion state of the first connector terminal T1 into the through hole 8a. FIG. Further, (b) is a diagram in which the insulator 1a of (a) is removed, and is a diagram showing the assembly relationship of the frame of the power supply module 81, the second connector terminal T2j, and the first connector terminal T1.

  The power supply module 81 shown in FIG. 2A is a power supply module sealed with an insulator (mold resin) 1a by transfer molding that supplies power to a load (the drive motor 10 shown in FIG. 1). . In the power supply module 81 of FIG. 2, a through hole 8 a for introducing the first connector terminal T <b> 1 shown in FIG. 1 of the load is formed in the insulator 1 a sealing the power supply module 81. A guide taper guide Ge that facilitates introduction of the first connector terminal T1 is provided at the introduction end of the first connector terminal T1 in the through hole 8a. Further, in the power supply module 81, the female second connector terminal T2j fitted to the male first connector terminal T1 is disposed on the opposite side of the surface of the main body Hh where the guide Ge is provided, and the main body It is joined to a power supply frame 2e protruding from the side surface of Hh and exposed from the insulator 1a. As shown in FIGS. 5A and 5B, the first connector terminal T1 of the load is inserted from above in FIG. 2 and passes through the through hole 8a of the insulator 1a. The terminal T1 and the second connector terminal T2j are fitted.

  As described with reference to FIG. 1, the through hole 8a formed in the power supply module 81 in FIG. 2A can have a function of roughly positioning the first connector terminal T1 of the load. By arranging the terminal T2j below the through hole 8a, it is possible to easily fit both terminals. Further, in the power supply module 81 in which the through hole 8a is formed, since the insulator 1a around the through hole 8a covers the second connector terminal T2j as shown in FIG. 1, the second connector terminal T2j The terminal cover can be eliminated. Note that the through hole 8a can be formed in advance at the time of molding the insulator of the power supply module 81, so that the cost is not increased.

  Further, in the power supply module 81 of FIG. 2, the guide Ge provided at the introduction end of the first connector terminal T1 in the through hole 8a is necessary particularly when the terminal cover of the second connector terminal T2j is eliminated. The guide Ge can also be formed in advance at the time of molding the insulator of the power supply module 81, so that the cost is not increased specially.

  As shown in FIG. 3, the main body Hh of the power supply module 81 of the three-phase AC inverter is sealed with an insulator 1 a, and 3 for power supply corresponding to the outputs of the U phase, the V phase, and the W phase, respectively. Two frames 2e protrude from the insulator 1a on the side surface of the main body Hh and are exposed. The frame 2e also serves as a suspension frame in the transfer molding process of the insulator 1a.

  Around the through hole 8a, as shown in FIG. 5B, a frame pattern 9 serving as an internal electric circuit is formed so as not to interfere with the first connector terminal T1 of the load inserted into the through hole 8a. ing. Moreover, the heat sink which consists of another flame | frame etc. is embedded in the insulator 1a, and the heat radiating surface 3 shown in FIG. 3 contacts the heat radiating member 31 shown in FIG. The power supply and control lead frame 4 is bent in an L shape and is connected to the printed circuit board 41 shown in FIG.

  Further, the second connector terminal T2j joined to the power supply frame 2e exposed from the insulator 1a of the main body Hh is joined with different functions as shown in FIGS. 4 (a) and 4 (b). It consists of a part Se, a fitting part Ka, an arm part Md, and a hook part Fb. The current conduction path to the load of the second connector terminal T2j shown in FIGS. 4 (a) and 4 (b) passes from the joint Se joined to the power supply frame 2e in FIG. It is a path | route which reaches the fitting part Ka fitted to the 1st connector terminal T1 of load.

  As shown in FIGS. 5A and 5B, the joining portion Se is a portion that joins the power supply frame 2e exposed from the insulator 1a of the main body Hh. Resistance welding is used for joining the joint portion Se between the frame 2e and the second connector terminal T2j. When projection welding is performed, a projection shape for projection welding is formed in the joint portion Se in advance.

  The fitting portion Ka is a part that fits into the first connector terminal T1 of the load, and has a female structure that fits into the male first connector terminal T1. Further, the fitting portion Ka of the second connector terminal T2j is composed of four pieces connected at one end shown in FIG. 4 (c), and a contact piece portion Ka1 formed in an annular shape and a cylindrical shape shown in FIG. 4 (d). And is formed of a separate cylindrical spring portion Ka2 that covers the contact piece Ka1. The contact piece portion Ka1 in FIG. 4C is punched and pressed from a single plate together with the arm portion Md, the joint portion Se, and the hook portion Fb, rounded by bending, and formed into an annular shape. In FIG.4 (c), the part protruded from the bottom part which has connected the four contact pieces is a part connected with the arm part Md. As shown in FIG. 4E, the cylindrical spring portion Ka2 in FIG. 4D is put on the contact piece portion Ka1. Further, with respect to the contact piece portion Ka1 and the cylindrical spring portion Ka2 assembled as shown in FIG. 4E, the resin-made cylindrical guide portion Ka3 shown in FIG. ). An insertion taper-shaped guide Ga is provided at the insertion end of the first connector terminal T1 in the cylindrical guide portion Ka3 to facilitate the insertion of the male first connector terminal T1 and guide it to the fitting position. With this guide Ga, the displacement of the fitting position that cannot be guided by the guide Ge of the main body Hh is finally corrected. Then, by inserting the first connector terminal T1 of the load into the center of the contact piece Ka1, a four-tangent (contact beam) fitting structure is completed. According to this, the energization current which can be used can be raised compared with the case where the contact beam shown later is two lines.

  The arm part Md is a part that can be elastically deformed and connects the joint part Se and the fitting part Ka. The arm portion Md has a function of correcting the misalignment between the center positions as follows when the fitting portion Ka is fitted to the first connector terminal T1 of the load. Since the first connector terminal T1 of the load is fixed, smooth fitting is performed by correcting the position of the fitting portion Ka through elastic deformation of the arm portion Md. More specifically, since the joint Se is welded and fixed when the first connector terminal T1 of the load is inserted into the fitting portion Ka, the displacement generated by the position correction of the fitting portion Ka is This is dealt with by elastic deformation of the arm portion Md. The second connector terminal T2j shown in FIGS. 4A and 4B is designed in a shape in which the deformation of the arm portion Md and the hook portion Fb is prioritized over the deformation of the fitting shape of the fitting portion Ka. In addition, the connection reliability and the connection resistance value of the fitting portion Ka are maintained. The shape of the arm portion Md is determined by the position and shape of the joining portion Se joined to the power supply frame 2e in FIG. 3, but basically has a shape close to an S shape.

  As described above, the second connector terminal T2j shown in FIG. 4 is fitted to the first connector terminal T1 by providing the elastically deformable arm portion Md between the joint portion Se and the fitting portion Ka. Even if there is a positional deviation or an angular deviation sometimes, it can be absorbed by elastic deformation of the arm portion Md. Therefore, even if there is a positional deviation or an angular deviation during fitting, unscheduled stress is not generated in the joint Se and the fitting part Ka of the second connector terminal T2j, and stable electrical connection is maintained. be able to.

  As shown in FIG. 5A, the hook portion Fb is caught by a part of the insulator 1a of the main body Hh when the male first connector terminal T1 of the load is inserted, and the displacement of the fitting portion Ka is detected. It is a part which restricts. The hook part Fb of the second connector terminal T2j is integrally formed with the contact piece part Ka1 in FIG.

  When the male first connector terminal T1 is pulled out, a predetermined portion of the lower surface of the insulator 1a of the main body Hh shown in FIG. 5A can be used as a portion that restricts the displacement of the fitting portion Ka. That is, when the first connector terminal T1 is pulled out, the upper surface of the fitting portion Ka of the second connector terminal T2j abuts against the lower surface of the insulator 1a of the main body Hh, and the upward displacement of the fitting portion Ka is limited. Is done. On the other hand, when the first connector terminal T1 is inserted, a displacement in the direction opposite to that at the time of extraction is generated in the fitting portion Ka. Without the hook portion Fb in FIGS. 4A and 4B, there is nothing to limit the downward displacement of the fitting portion Ka, so the fitting portion Ka, the arm portion Md, and the joint portion Se have a downward direction. There is a case in which a tensile stress is applied to the arm portion, the S-shape of the arm portion Md is unwound, and the arm portion Md loses elastic deformation. Therefore, in order to prevent excessive stress from being generated in the fitting portion Ka, the arm portion Md, and the joint portion Se when the first connector terminal T1 is inserted, it is preferable to provide the hook portion Fb by integral molding.

  FIG. 6 is a view showing a modification of the power supply module 81 shown in FIG. 2, and (a) and (b) are perspective views of the power supply module 82 as viewed from above and below, respectively.

  FIG. 7 is a diagram viewed from above in FIG. 6A, and is an enlarged view of the periphery of the through hole 8 b of the power supply module 82.

  FIG. 8 is a view showing the main body Hi of the power supply module 82 before joining the second connector terminal T2k, and (a) and (b) are perspective views of the main body Hi as viewed from above and below, respectively. . In the main body Hi of the power supply module 82 shown in FIG. 8, the same reference numerals are given to the same parts as those of the main body Hh of the power supply module 81 shown in FIG.

  FIG. 9 is an enlarged perspective view of the second connector terminal T2k used in the power supply module 82 of FIG.

  The power supply module 82 shown in FIG. 6 is also a power supply module sealed with an insulator (mold resin) 1a by transfer molding that supplies power to the load (the drive motor 10 shown in FIG. 1). 6 also introduces the first connector terminal T1 shown in FIG. 1 of the load as shown in FIGS. 7 and 8 as in the case of the power supply module 81 shown in FIG. A through hole 8 b is formed in the insulator 1 a that seals the power supply module 82. A guide taper guide Ge that facilitates introduction of the first connector terminal T1 is provided at the introduction end of the first connector terminal T1 in the through hole 8b.

  On the other hand, in the power supply module 81 shown in FIG. 2, the female second connector terminal T2j fitted to the male first connector terminal T1 of the load protrudes from the side surface of the main body Hh and is exposed from the insulator 1a. It was joined to the power supply frame 2e. On the other hand, in the power supply module 82 of FIG. 6, the female second connector terminal T2k fitted to the male first connector terminal T1 of the load is recessed from the upper and lower surfaces of the main body Hi and from the insulator 1a. It is joined to the exposed frame 2a for power supply. The first connector terminal T1 of the load is inserted into the second connector terminal T2k from above in FIG. 6A, and the first connector terminal T1 and the second connector terminal T2k are fitted.

  A groove 9a shown in FIG. 8A is formed in the main body Hi of the power supply module 82, and the second connector terminal T2k is disposed in this portion. The insulator 1a existing between the grooves 9a serves as a wall that ensures a creepage distance between the adjacent second connector terminals T2k.

  The second connector terminal T2k is joined to the power supply frame 2a exposed from the insulator 1a in FIG. 6B by resistance welding. For this reason, as shown in FIG. 6A and FIG. 7, a welding hole 5 for inserting one electrode of resistance welding is provided on the opposite surface of the main body Hi. It is formed on the insulator 1a so as to expose the surface of the frame 2a opposite to that shown in FIG.

  As shown in FIG. 9, the second connector terminal T2k includes a joint portion Sa, a fitting portion Kb, an arm portion Ma, and a hook portion Fb. The second connector terminal T2k shown in FIG. 9 has a fitting portion Kb having a different configuration from the second connector terminal T2j shown in FIG.

  The fitting portion Ka of the second connector terminal T2j shown in FIG. 4 is composed of four pieces connected at one end of FIG. 4 (c), and is formed into a ring-shaped contact piece Ka1 and the cylinder of FIG. 4 (d). It is formed into a shape and has a spring property, and is composed of a separate cylindrical spring portion Ka2 that covers the contact piece portion Ka1, and has a four-tangent fitting structure. On the other hand, the fitting portion Kb in the second connector terminal T2k in FIG. 9 has a two-tangent fitting structure, and can be energized basically up to about half the current of four tangents. In the second connector terminal T2k shown in FIG. 9, the contact resistance can be reduced and the energization current can be increased by lengthening the fitting portion Kb in contact with the first connector terminal T1. Further, at the insertion end of the first connector terminal T1 in the fitting portion Kb of the second connector terminal T2k shown in FIG. 9, an invitation taper that facilitates the insertion of the male first connector terminal T1 and leads it to the fitting position. A guide Gf having a shape is provided. This guide Gf finally corrects the displacement of the fitting position that cannot be guided by the guide Ge of the main body Hi.

  On the other hand, the second connector terminal T2k in FIG. 9 is different from the second connector terminal T2j in FIG. 4, and the entire joint portion Sa, fitting portion Kb, arm portion Ma, and hook portion Fb are as shown below. It is integrally formed by bending. Therefore, the second connector terminal T2k in FIG. 9 can be manufactured at a lower cost than the second connector terminal T2j in FIG.

  FIGS. 10A to 10C and FIGS. 11A to 11C are views showing a manufacturing process of the second connector terminal T2k of FIG.

  The second connector terminal T2k in FIG. 9 is formed from one of the Sn-plated copper alloy plates punched and pressed into the developed shape shown in FIG. 10A through the subsequent bending processes.

  First, as shown in FIG. 10A, the base material of the second connector terminal T2k is punched into the shape shown in the drawing. Next, bending is performed in the direction of the arrow in the figure, and the fitting portion is primarily formed.

  FIG.10 (b) is the state by which the said fitting part was primary-molded. Next, bending is performed in the direction of the arrow in the figure, and the arm portion Ma is bent by 90 °. Also, T-shaped hanging portions provided on the upper and lower sides in order to maintain the shape of the fitting portion are bent in the direction of the arrow in the figure, and hung on the opposing concave portions.

  FIG. 10C shows a state where the fitting portion Kb is finally molded. Next, in order to form a hook part, the connection part with the fitting part Kb is bent in the direction of the arrow in the figure and is primarily formed.

  FIG. 11A shows a state in which the connecting portion is primarily molded. Next, the joint is bent 90 ° in the direction of the arrow in the figure.

  FIG. 11B shows a state where the joint portion Sa is formed. Next, the hook portion is bent in the direction of the arrow in the figure.

  FIG. 11C shows a state where the hook portion Fb is molded. Thus, the molding is completed, and the second connector terminal T2k in FIG. 9 is manufactured.

  The welding process of the second connector terminal T2k to the main body Hi is performed as follows.

  First, the second connector terminal T2k is inserted and aligned with the main body Hi as shown in FIG. 6, and set at a predetermined position on the main body Hi. In this state, as shown in FIG. 7, the second connector terminal T2k is arranged so that the hook portion Fb is hooked on a part of the insulator 1a of the main body Hi. Further, on the opposite surface shown in FIG. 6B, the joining portion Sa hidden in the back of the drawing is on a predetermined position of the power supply frame 2a of FIG. 8B exposed from the insulator 1a. A second connector terminal T2k is disposed.

  Resistance welding is used for joining the joint portion Sa of the second connector terminal T2k and the frame 2a. Of the two welding electrodes, one welding electrode is such that the tip presses the position of the projection (protrusion) formed at the joint portion Sa of the second connector terminal T2k from the side shown in FIG. 6 (b). set. The other welding electrode is set so as to press the frame 2a of FIG. 7 exposed from the welding hole 5 provided at the main body Hi from the side shown in FIG. 6 (a). Then, the joining portion Sa and the frame 2a of the second connector terminal T2k are sandwiched between the two welding electrodes from both sides, and a large current is passed through the surface of the frame 2a, which is a welded joint portion, and the contact portion of the joining portion Sa. Thereby, the contact portion is heated and melted by the resistance heat generated in the contact portion, and the frame 2a and the second connector terminal T2k are welded.

  As described above, in the power supply module according to the present invention, the second connector terminal is preferably joined to the frame exposed from the insulator by resistance welding having a high joining strength in a short time. However, the present invention is not limited to this, and another joining method such as soldering may be used.

  Further, when the second connector terminal is joined to the frame by resistance welding, as shown in FIG. 6, the surface opposite to the exposed surface of the frame 2a to which the joint portion Sa of the second connector terminal T2k is joined is formed. The exposed welding holes 5 are formed in the insulator 1a. According to this, it is possible to minimize the exposure from the insulator 1a of the power supply frame 2a that joins the second connector terminal T2k. However, the present invention is not limited to this, and, like the power supply module 81 shown in FIG. 2, adopts another structure in which two welding electrodes can be easily set by changing the exposure form of the power supply frame from the main body. It is also possible to do.

  FIG. 12 is a view showing a modification of the power supply module 82 shown in FIG. 6, and is a perspective view of the periphery of the second connector terminal T2l of the power supply module 83 as seen from below, similar to FIG. 6B. .

  FIG. 13 is an enlarged perspective view of the second connector terminal T21 used in the power supply module 83 of FIG.

  The power supply module 83 in FIG. 12 uses the same main body Hi in FIG. 8 as the power supply module 82 in FIG. 6, and only the second connector terminal T2l joined to the power supply frame 2a is shown in FIG. This is different from the second connector terminal T2k in the power supply module 82.

  The second connector terminal T2k used in the power supply module 82 in FIG. 6 has a structure that follows the male first connector terminal T1 of the load when there is a positional deviation or an angular deviation during fitting. Therefore, the arm part Ma is provided.

  On the other hand, the second connector terminal T2l of the power supply module 83 shown in FIG. 13 has a structure in which the arm portion Ma is omitted from the structure of the second connector terminal T2k of the power supply module 82 shown in FIG. Yes. The second connector terminal T2l used in the power supply module 83 of FIG. 12 is applicable when the male first connector terminal of the load has a structure that follows the fitting position.

  As described above, the power supply module according to the present invention described above is a power supply module sealed with an insulator that supplies power to the load, and includes the first connector terminal of the load and the second power supply module. It is possible to absorb the deviation from the proper fitting position due to the connector terminal assembly error, etc., and further, the load and the power supply module can be directly electrically connected via the second connector terminal. A simple power supply module can be obtained.

  Therefore, in the power supply module, for example, the load is a drive motor of an electric compressor mounted on an automobile and the power supply module is an inverter module that supplies power to the drive motor. Suitable for electric compressors.

  By using the power supply module, it is possible to absorb a shift from an appropriate fitting position due to an assembly error or the like and stably connect the first connector terminal of the load and the second connector terminal of the power supply module. Can do. Furthermore, since no lead wire or printed circuit board is interposed in the power supply line from the power supply module, the solder connection point of the power supply line via the printed circuit board and the connector, which is a problem in the conventional power supply module, can be eliminated. At the same time, the size can be greatly reduced.

  In the examples of the power supply modules 80 to 83 shown above, the insulator 1a sealing the main bodies Hh and Hi is a mold resin by transfer molding. For the insulator 1a sealing the power supply module, a mold resin by transfer molding is widely used. However, the power supply module according to the present invention is not limited to this, and may be a power supply module using a ceramic package as a sealing insulator, or a power supply module sealed with resin by potting.

  Further, as described above, since the second connector terminal is retrofitted to a power supply module sealed with an insulator and installed outside the insulator, the degree of freedom in shape selection is high. Therefore, as in the example described above, the first connector terminal of the load is a male terminal, and the second connector terminal joined to the power supply frame is generally used for the male first connector terminal. It may be a female terminal having a complicated shape. However, the present invention is not limited to this, and in the power supply module according to the present invention having a through hole for introducing the first connector terminal of the load, the first connector terminal of the load is a female terminal, and the second power supply module side second terminal is provided. The connector terminal may be a male terminal. For example, the power supply frame protruding from the insulator of the power supply module is used as the male second connector terminal, and the first connector terminal of the female load formed in a cylindrical shape is used. It leads to the previous second connector terminal through a through hole provided in the insulator of the power supply module. Accordingly, it is possible to absorb a deviation from an appropriate fitting position due to an assembly error between the first connector terminal of the load and the second connector terminal of the power supply module. Further, the first connector terminal and the second connector terminal The load and the power supply module can be directly electrically connected via the connector terminal.

20, 80-83 Power supply module Hh, Hi body 1a Insulator (mold resin)
8, 8a Through hole 2a, 2e (for power supply) Frame T2, T2j to T2l Second connector terminal Sa, Se Joint portion Ka, Kb Fitting portion Ma, Md Arm portion Fb Hook portion

Claims (14)

A power supply module (80 to 83) sealed with an insulator (1a) for supplying power to a load,
A power supply module, wherein a through hole (8, 8a) for introducing the first connector terminal (T1) of the load is formed in the insulator.   The power supply module according to claim 1, wherein the insulator is a mold resin.   The taper-shaped guide (Ge) for facilitating introduction of the first connector terminal is provided at the introduction end of the first connector terminal in the through hole. Power supply module.   The second connector terminals (T2j to T2l) fitted to the first connector terminals introduced into the through holes are joined to the power supply frames (2a, 2e) exposed from the insulator. The power supply module according to claim 1, wherein the power supply module is a power supply module. The second connector terminal is
Joining parts (Sa, Se) joined to the frame, fitting parts (Ka, Kb) fitted to the first connector terminals, and arm parts (elastically deformable and connecting the joining parts and the fitting parts) Ma, Md), and the power supply module according to claim 4. The first connector terminal is a male terminal;
The power supply module according to claim 5, wherein the second connector terminal is a female terminal.   The power supply module according to claim 5 or 6, wherein the joint portion (Sa), the fitting portion (Kb), and the arm portion (Ma) are integrally formed by bending. The fitting portion (Ka) is
It consists of four pieces connected at one end, and a contact piece part (Ka1) formed into an annular shape,
The power supply module according to claim 6, wherein the power supply module is formed of a separate cylindrical spring portion (Ka 2) that is formed in a cylindrical shape and has a spring property and covers the contact piece portion.   The hook portion (Fb) is formed integrally with the second connector terminal, and is hooked to a part of the insulator when the first connector terminal is inserted to limit the displacement of the fitting portion. The power supply module according to claim 6 or 8.   The taper-shaped guide (Ga, Gf) for facilitating insertion of the first connector terminal is provided at the insertion end of the first connector terminal in the fitting portion. The power supply module according to claim 1.   The power supply module according to claim 4, wherein the joining is resistance welding.   A hole for inserting one electrode of the resistance welding, the welding hole (5) exposing the surface opposite to the exposed surface of the frame to which the second connector terminal is joined, is the insulator. The power supply module according to claim 11, wherein the power supply module is formed as follows.   The power supply module according to any one of claims 4 to 11, wherein the frame (2e) protrudes from the insulator and is exposed. The load is a drive motor (10) of an electric compressor mounted on an automobile,
The power supply module according to any one of claims 1 to 13, wherein the power supply module is an inverter module that supplies power to the drive motor.

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