JP2014143899A - Resin molding for electric motor, electric motor, electric pump and manufacturing method of resin molding for electric motor - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a resin molding for an electric motor which is capable of improving molding accuracy and can be small-sized while securing a required strength, an electric motor, an electric pump and a manufacturing method of the resin molding for the electric motor.SOLUTION: A resin molding 153 comprises a primary molding part 154 for integrating a signal system terminal bus bar and power terminal bus bars 102a, 102b, and a secondary molding part 155 for performing insert molding on the primary molding part 154. The secondary molding part 155 includes a peripheral wall portion 162 forming a peripheral wall of a connector part 58, a secondary connector body portion 161 integrally molded at a proximal end side of the peripheral wall portion 162, and a base body 165 integrating the power bus bars 103a, 103b and three-phase bus bars 104a-104c.

Description

  The present invention relates to a resin molded product for an electric motor, an electric motor, an electric pump, and a method for manufacturing the resin molded product for an electric motor.

For example, an electric pump is used to pump oil to a drive motor of a hybrid vehicle or a gear box connected to the drive motor. The electric pump includes a pump unit, a motor unit that drives the pump unit, and a driver unit that controls the motor unit.
The driver portion includes a driver assembly including a substrate and a resin base in a space defined by the end of the motor housing and the cover. The pedestal is formed with a connector portion, and the connector portion is provided with connector terminals for electrically connecting the power source and the substrate.
Here, one end of the connector terminal protrudes from the connector portion, and the other end is insert-molded in the base. The other end of the connector terminal is exposed to the outside of the pedestal at a predetermined location and connected to the substrate (for example, see Patent Document 1).

JP 2012-92742 A

By the way, in the above-mentioned prior art, when resin molding is performed on the pedestal, if there are portions with different resin thicknesses, there is a problem that resin sink marks (shrinkage) occur during molding, and it is difficult to achieve desired molding accuracy. is there.
In order to suppress the occurrence of sink marks, it may be possible to steal the resin molded product or the like. However, depending on the thickness, it is difficult to ensure the strength of the resin molded product. In particular, when the connector part is integrally formed on the pedestal, the connector part needs to be strong enough to withstand the attachment and detachment of the connector extending from the external device. is there.

  Accordingly, the present invention has been made in view of the above-described circumstances, and is capable of improving molding accuracy, and can be miniaturized while ensuring necessary strength, an electric motor, and an electric pump. And the manufacturing method of the resin molded product for electric motors is provided.

  In order to solve the above-described problems, a resin molded product for an electric motor according to the present invention includes a first terminal group and a second terminal group each including a plurality of terminals embedded in a resin main body and extending from an external device. A resin molded product for an electric motor in which a connector portion to which a connector can be fitted is integrally formed, wherein the resin main body integrates the first terminal group, and one end of the first terminal group projects into the connector portion. A primary molding part that functions as a connector terminal to be configured, and a secondary molding part that insert-molds the primary molding part, and the secondary molding part includes a peripheral wall part that forms a peripheral wall of the connector part, and A connector main body formed so as to embed at least a part of the primary molding portion and integrally formed on the base end side of the peripheral wall portion, and integrally formed on the base end side of the connector main body portion While being, characterized in that it is constituted by a base portion for integrating the second terminal group.

By comprising in this way, the thick location of the connector part which requires the intensity | strength of the resin molded product for electric motors can be divided into a primary molding part and a secondary molding part. Thereby, the thickness nonuniformity at the time of shape | molding each shaping | molding part can be suppressed to the minimum, and the shaping | molding precision of the resin molded product for electric motors can be improved.
Moreover, since the thickness unevenness at the time of molding each molded part is reduced, it is possible to minimize the stealing of a portion where strength is required for the entire resin molded product for an electric motor. Furthermore, it is not necessary to increase the thickness of the entire resin molded product for an electric motor in accordance with a location where strength is required. For this reason, the resin molded product for electric motors can be reduced in size while ensuring the required strength.

  In the resin molded product for an electric motor according to the present invention, a first connection portion that connects these terminals to each other is formed in at least a part of the plurality of terminals constituting the first terminal group, and the first connection portion is It arrange | positions so that it may be exposed to the outer side of a primary molding part, It is characterized by the above-mentioned.

With this configuration, it is not necessary to position each terminal individually when forming the primary molded portion. For this reason, the manufacturing process of a primary molding part can be simplified.
Further, since the first connecting portion is disposed so as to be exposed to the outside of the primary molding portion, each terminal can be reliably separated after molding the primary molding portion.

  In the resin molded product for an electric motor according to the present invention, a second connecting portion that connects these terminals to each other is formed in at least a part of the plurality of terminals that constitute the second terminal group. It arrange | positions so that it may be exposed to the outer side of a secondary molding part, It is characterized by the above-mentioned.

By configuring in this way, it is not necessary to position each terminal individually when forming the secondary molded part. For this reason, the manufacturing process of a secondary formation part can be simplified.
Further, since the second connecting portion is disposed so as to be exposed to the outside of the secondary molding portion, each terminal can be reliably separated after the secondary molding portion is formed.

  The resin molded product for an electric motor according to the present invention is characterized in that an opening that penetrates in the thickness direction is formed in the base portion, and the second connecting portion is exposed to the outside through the opening. To do.

  By comprising in this way, even if it is a case where substantially the whole 2nd terminal group is embed | buried under a base part, each terminal of a 2nd terminal group can be isolate | separated reliably.

  In the resin molded product for an electric motor according to the present invention, the connector main body portion is erected so as to be substantially orthogonal to the base portion, and a flat surface is formed around the connector main body portion of the base portion. The flat surface is configured as a seal surface for securing a sealing property between the resin main body and the fixed member.

  Here, since the molding accuracy of the resin molded product for an electric motor is improved, the flatness of the flat surface can also be improved. For this reason, since it becomes possible to overlap the circumference | surroundings of a connector part and a to-be-fixed member with high precision, the sealing performance between a connector part and a to-be-fixed member can be improved.

  In the resin molded product for an electric motor according to the present invention, a flange portion is formed in a portion corresponding to a base end portion of the connector portion in the primary molding portion, and the flat surface is formed so as to cover the flange portion. It is characterized by.

  Thus, by forming the flange portion in the primary molding portion in advance, it is not necessary to increase the thickness of the flat surface when forming the secondary molding portion. For this reason, when forming a secondary molding part, it becomes possible to raise the flatness of a flat surface easily.

  An electric motor according to the present invention includes a resin molded product for an electric motor, a motor housing that is a fixed member to which the resin molded product for the electric motor is fixed, and the motor housing that is accommodated in the motor housing. And a rotor that is electrically connected to an external device and a rotor that is rotatably supported in the motor housing.

  By comprising in this way, the small electric motor with the high sealing performance between a motor housing and the resin molded product for electric motors can be provided.

  The electric pump according to the present invention includes an electric motor and a pump unit integrated with the motor housing and driven by the electric motor.

  By comprising in this way, a small electric pump can be provided, ensuring the intensity | strength of a connector part.

  In the method for manufacturing a resin molded product for an electric motor according to the present invention, a first terminal group and a second terminal group constituted by a plurality of terminals are embedded in a resin main body, and a connector extending from an external device can be fitted. A method for producing a resin molded product for an electric motor in which a connector portion is integrally formed, wherein the first terminal group is integrated, and one end of the first terminal group is a connector terminal protruding into the connector portion. A primary molding step for forming a secondary molding portion, a peripheral wall portion constituting the peripheral wall of the connector portion, and a connector main body integrally formed on the proximal end side of the peripheral wall portion so that the primary molding portion is embedded And a secondary molding step of forming a secondary molding part integrally formed on the base end side of the connector main body part and a base part for integrating the second terminal group. To.

By adopting such a manufacturing method, it is possible to divide the thick part of the connector part, which requires the strength of the resin molded product for an electric motor, into a primary molded part and a secondary molded part, and mold each molded part. It is possible to improve the molding accuracy of the resin molded product for an electric motor by eliminating the uneven thickness.
In addition, it is possible to minimize theft of meat that requires strength as a whole resin molded product for electric motors, and it is also necessary to increase the thickness of the entire resin molded product for motors according to the location where strength is required. Disappear. For this reason, the resin molded product for electric motors can be reduced in size while ensuring the required strength.

  In the method for producing a resin molded product for an electric motor according to the present invention, the primary molding step is performed in a state where at least a part of the plurality of terminals constituting the first terminal group is connected in advance, and the primary molding is performed. After forming the section, it has a primary separation step of separating each terminal.

  By setting it as such a manufacturing method, it is not necessary to position each terminal individually, and a primary formation process can be simplified. Moreover, each terminal can be reliably separated after forming the primary molding part.

  In the method for manufacturing a resin molded product for an electric motor according to the present invention, the secondary molding step is performed in a state where at least a part of the plurality of terminals constituting the second terminal group is connected in advance, and the secondary molding is performed. After forming the section, it has a secondary separation step of separating each terminal.

  By setting it as such a manufacturing method, it is not necessary to position each terminal individually, and a secondary molding process can be simplified. Moreover, each terminal can be reliably separated after forming the secondary molded part.

  In the method for producing a resin molded product for an electric motor according to the present invention, in the secondary molding step, an opening that penetrates in the thickness direction is formed in the base portion, and the opening constitutes the second terminal group. It is formed so that the site | part which has connected the said some terminal to be exposed may be exposed.

  By adopting such a manufacturing method, each terminal of the second terminal group can be reliably separated even when almost the entire second terminal group is embedded in the base portion.

  In the method for manufacturing a resin molded product for an electric motor according to the present invention, the connector main body portion is erected so as to be substantially orthogonal to the base portion, and the secondary molding step includes the connector of the base portion. The present invention is characterized in that a flat surface is formed around the main body.

  By setting it as such a manufacturing method, since it becomes possible to overlap the circumference | surroundings of a connector part and a to-be-fixed member with high precision, the sealing performance between a connector part and a to-be-fixed member can be improved.

  In the method for producing a resin molded product for an electric motor according to the present invention, the primary molding step is performed so as to form a flange portion at a portion corresponding to a base end portion of the connector portion in the primary molded portion, The flat surface is formed so as to cover the flange portion.

  By adopting such a manufacturing method, it is not necessary to increase the thickness of the flat surface when forming the secondary molded portion, and the flatness of the flat surface is easily increased when forming the secondary molded portion. It becomes possible.

According to the present invention, the thick portion of the connector portion where the strength of the resin molded product for an electric motor is required can be divided into a primary molded portion and a secondary molded portion. Thereby, the thickness nonuniformity at the time of shape | molding each shaping | molding part can be suppressed to the minimum, and the shaping | molding precision of the resin molded product for electric motors can be improved.
Moreover, since the thickness unevenness at the time of molding each molded part is reduced, it is possible to minimize the stealing of a portion where strength is required for the entire resin molded product for an electric motor. Furthermore, it is not necessary to increase the thickness of the entire resin molded product for an electric motor in accordance with a location where strength is required. For this reason, the resin molded product for electric motors can be reduced in size while ensuring the required strength.

It is a perspective view of the electric pump in the embodiment of the present invention. It is a longitudinal cross-sectional view of the electric pump in embodiment of this invention. It is a principal part disassembled perspective view of the electric pump in embodiment of this invention. It is the appearance perspective view which looked at the control device in the embodiment of the present invention from the inner side of the motor case. It is an external appearance perspective view when the control apparatus in embodiment of this invention is seen from the outer side of a motor case. It is a top view when the bus-bar unit main body in embodiment of this invention is seen from the 2nd main surface side. It is a longitudinal cross-sectional view of the bus-bar unit main body in embodiment of this invention. It is the perspective view which permeate | transmitted the secondary shaping | molding part of the bus-bar unit main body in embodiment of this invention. It is a perspective view of the primary formation part in the embodiment of the present invention. It is a top view of the primary formation part in the embodiment of the present invention. It is a perspective view of a signal system terminal bus bar and a power terminal bus bar in an embodiment of the present invention. It is manufacturing process explanatory drawing of the bus-bar unit main body in embodiment of this invention, Comprising: (a)-(f) shows each process. It is a flowchart of the manufacturing process of the bus-bar unit main body in embodiment of this invention.

(Electric pump)
Next, embodiments of the present invention will be described with reference to the drawings.
FIG. 1 is a perspective view of an electric pump, and FIG. 2 is a longitudinal sectional view including a central axis O of the electric pump.
As shown in FIGS. 1 and 2, the electric pump 1 is for pumping oil to, for example, a drive motor of a hybrid vehicle, a gear box connected to the drive motor, or the like. The electric pump 1 includes a housing 10, a brushless motor 20 housed in the housing 10, a control device 50 for controlling the brushless motor 20, and a pump provided outside the housing 10 and driven by the brushless motor 20. Part 90.
Here, the brushless motor 20 and the pump unit 90 have a common central axis with the central axis O of the electric pump 1. In the following description, a direction along the central axis O is referred to as an axial direction, a direction orthogonal to the central axis O is referred to as a radial direction, and a direction around the central axis O is referred to as a circumferential direction.

As shown in FIG. 2, the housing 10 is made of a metal material, and is formed by die-casting an aluminum material in the present embodiment. The housing 10 has a bottomed cylindrical motor case 11 having an opening 12 on one axial side (right side in FIG. 2) and a bottom 13 on the other axial side (left side in FIG. 2). The cover member 46 is attached to the opening 12 side of the motor case 11.
A brushless motor 20 is disposed inside the motor case 11, and a controller 50 is disposed so as to be integrally connected to an end portion in the axial direction on the opening 12 side of the motor case 11. A pump portion 90 is disposed so as to be integrally connected to the other end portion (outer end surface 14) which is the bottom portion 13 side.

(Brushless motor)
The motor case 11 has a substantially cylindrical tube portion 11a, and a stator 21 is fixed to the inner peripheral surface of the tube portion 11a by adhesion, press fitting, or the like. The stator 21 is formed by a substantially cylindrical stator core 21a. The stator core 21a is formed by laminating a plurality of metal plates (electromagnetic steel plates) in the axial direction, which are punched in a substantially annular shape in a state of being divided into a predetermined number (for example, 9 in the present embodiment) in the circumferential direction by, for example, pressing. Thus, a plurality of teeth 23 (for example, nine in the present embodiment) for winding the coil 26 are formed radially.

  A slot (not shown) is formed between the teeth 23. Nine slots are formed at equal intervals along the circumferential direction. An insulator 25, which is an insulating material, is attached to each tooth 23 over the entire circumference, and a coil 26 corresponding to the three phases of the U phase, the V phase, and the W phase is wound on the insulator 25. That is, the brushless motor 20 of this embodiment is a three-phase brushless motor provided with a three-phase coil 26 of U phase, V phase, and W phase.

A terminal portion of the coil 26 wound around each tooth 23 is drawn toward the opening 12 side of the motor case 11 and connected to a bus burring unit 28 disposed in the opening 12.
The bus burring unit 28 is for supplying electric power from the outside to the coil 26. The bus burring unit 28 is provided with a plurality of (four in this embodiment) buses made of metal in a substantially annular ring holder 28a made of an insulating material. A burring 28b is embedded and formed. A terminal portion of a predetermined coil 26 is electrically connected to each bus bar ring 28b and assigned to each phase bus bar.

  Specifically, a U-phase bus bar, a V-phase bus bar, and a W-phase bus bar connected to a winding start end (not shown) of each phase coil 26, and a winding end end (not shown) of each phase coil 26. ) And a neutral point bus bar to be connected. The U to W-phase bus bars include power supply terminals 29 a to 29 c that are erected along the axial direction toward the opening 12 side of the motor case 11. The power supply terminals 29 a to 29 c are electrically connected to the motor control unit 71 of the control device 50.

  A bearing holder 4 formed by press-molding a steel plate material is provided at the end of the motor case 11 on the opening 12 side in order to close the opening 12 of the motor case 11. A cylindrical bearing holding portion 4 a disposed inside the bus burring unit 28 is formed at the center of the bearing holder 4. A bearing 5 is fitted in the bearing holding portion 4a.

The bottom portion 13 of the motor case 11 has a substantially rectangular cross section along the axial direction, and has a predetermined thickness in the axial direction. A shaft insertion hole 13 a that penetrates the bottom portion 13 along the axial direction is formed in the central portion in the radial direction of the bottom portion 13 of the motor case 11. Further, in the bottom portion 13 of the motor case 11, a bearing holding portion 13b having a smaller diameter than the cylindrical portion 11a and a seal holding portion 13c having a smaller diameter than the bearing holding portion 13b are opened in this order. They are provided side by side from the 12 side toward the bottom 13 side.
The bearing 6 is fitted in the bearing holding portion 13b. In addition, a ring-shaped oil seal 7 for preventing oil from entering the motor case 11 is fitted in the seal holding portion 13c.

  A rotor 31 is provided inside the stator 21 in the radial direction. The rotor 31 includes a rotating shaft 35, a rotor core 32 fixed to the outer peripheral surface of the rotating shaft 35, a plurality of magnets 33 disposed on the outer peripheral surface of the rotor core 32 along the circumferential direction, and the magnets 33 to the rotor core 32. A magnet cover 33a for holding and a magnet holder 33b are provided. As with the stator 21, the rotor core 32 is configured by laminating a plurality of metal plates (electromagnetic steel plates) punched in a substantially annular shape by, for example, press working in the axial direction. Each magnet 33 is arranged on the outer side in the radial direction of the rotor core 32 so that the magnetic poles are alternately changed in the circumferential direction.

  The rotating shaft 35 is supported by a bearing 5 provided on the bearing holder 4 and a bearing 6 provided on the bottom 13 of the motor case 11. Thereby, the rotor 31 is rotatably supported coaxially with the central axis O on the inner side in the radial direction of the stator 21. One end 35 a of the rotating shaft 35 is disposed at the end of the opening 12 of the motor case 11. The other end 35 b of the rotating shaft 35 is inserted through the bearing 6, the oil seal 7, and the shaft insertion hole 13 a and protrudes outward from the outer end surface 14 of the bottom 13 of the motor case 11.

  Further, inside the bottom portion 13 of the motor case 11, a suction port 16 that communicates the outside of the motor case 11, which is one radial side surface 15 a (see FIG. 1), and the outer end surface 14 of the bottom portion 13, and A discharge port 17 is integrally formed. The suction port 16 and the discharge port 17 communicate with each other in a pump portion 90 provided so as to be integrally connected to the outer end surface 14 of the bottom portion 13 of the motor case 11. Thus, as will be described later, when the electric pump 1 fastened and fixed to a mounted body such as a gear box is driven, even if the oil being pumped itself has heat, the heat is sucked into the suction port 16 and the discharge port 17. To the motor case 11 made of a metal material. In particular, the heat of oil can be effectively diffused by forming the motor case 11 from an aluminum material having good thermal conductivity.

(Pump part)
The pump unit 90 is a so-called trochoid pump, and includes a pump case 91 attached to the outer end surface 14 of the motor case 11, an inner rotor 92 and an outer rotor 93 provided in the pump case 91, and a pump case 91 from the outside in the axial direction. And a pump cover 94 for covering. The pump case 91 is formed in a frame shape from a metal material such as iron (carbon steel) or aluminum, and the inside is a substantially circular pump housing portion 91a as viewed in the axial direction.

  The pump storage portion 91a is eccentric with respect to the central axis O. The pump case 91 is fastened to the outer end surface 14 of the motor case 11 by, for example, screwing a plurality of bolts 96 or the like, and between the outer end surface 14 of the motor case 11 and the pump case 91 in the circumferential direction. An O-ring 97 is arranged over the entire circumference. Thereby, the sealing performance between the outer end surface 14 of the motor case 11 and the pump cover 94 is ensured.

The inner rotor 92 is made of, for example, a metal material such as iron (carbon steel) or aluminum, and has a plurality (seven in this embodiment) of external teeth. The inner rotor 92 performs, for example, two-side machining on the other end 35b (the left end in FIG. 2) of the rotary shaft 35, and the inner rotor 92 is relatively movable in the axial direction and circumferentially. Is supported in a state in which relative movement is impossible.
The outer rotor 93 is formed of a metal material such as iron (carbon steel) or aluminum, for example, like the inner rotor 92, and can mesh with the outer teeth of the inner rotor 92, and there are a plurality of outer rotors 93 that are larger than the outer teeth of the inner rotor 92. It has 8 internal teeth (8 in this embodiment). The outer rotor 93 is formed such that its outer diameter is slightly smaller than the inner diameter of the pump housing portion 91a. As the inner rotor 92 rotates, the outer rotor 93 rotates while a part of the outer peripheral surface of the outer rotor 93 is supported by the inner peripheral surface of the pump housing portion 91a.

  A pump chamber 95 is formed between the outer teeth of the inner rotor 92 and the inner teeth of the outer rotor 93 that mesh with each other. The pump chamber 95 is formed so that its volume increases and decreases as the inner rotor 92 and the outer rotor 93 rotate, and communicates with the suction port 16 and the discharge port 17. When the volume of the pump chamber 95 increases, oil is sucked into the pump chamber 95 from the outside of the pump chamber 95 through the suction port 16, and when the volume decreases, the pump chamber 95 passes through the discharge port 17 from the pump chamber 95. Oil is discharged outside.

The pump cover 94 is formed of, for example, a metal material such as iron (carbon steel) or aluminum, and is fixed to the pump case 91 from the outside in the axial direction with a bolt (not shown) or the like. An O-ring 98 is mounted between the pump case 91 and the pump cover 94 over the entire circumference. Thereby, the sealing performance between the pump case 91 and the pump cover 94 is ensured.
When the pump case 91 is fastened to the outer end surface 14 of the motor case 11 by a plurality of bolts 96, the O-ring 97 and the O-ring 98 are compressed in the axial direction, thereby exhibiting the sealing performance of each part. .

  As shown in FIG. 1, an electric pump mounting portion 15 that projects outward is formed on one side surface 15 a in the radial direction of the bottom portion 13 of the motor case 11. A plurality of mounting holes 15 b are formed in the electric pump mounting portion 15. The electric pump 1 is attached to the attached body by fastening a bolt (not shown) inserted through the attachment hole 15b to the attached body such as a gear box. As a result, the suction port 16 and the discharge port 17 are configured to communicate with the inside of the mounted body and to feed oil into the mounted body.

FIG. 3 is an exploded perspective view of a main part of the electric pump.
As shown in the figure, at the end of the motor case 11 on the opening 12 side, a control device arrangement portion 40 for attaching the control device 50 is integrally formed outside the bearing holder 4 in the axial direction. Yes. The control device disposing portion 40 is formed in a substantially rectangular shape when viewed from the axial direction, and a disposing opening 41 communicating with the opening portion 12 of the motor case 11 is formed in most of the control device disposing portion 40. A flange portion 42 is formed at one end portion in the longitudinal direction of the control device arrangement portion 40 so as to project outward in the radial direction of the motor case 11 when viewed from the axial direction. A through hole 43 penetrating in the axial direction is formed at the center of the flange portion 42.

(Control device)
4 is an external perspective view of the control device as viewed from the inside of the motor case, and FIG. 5 is an external perspective view of the control device as viewed from the outside of the motor case.
As shown in FIGS. 4 and 5, the control device 50 includes a substantially plate-like bus bar unit main body 53 that mainly forms a main body portion, a motor drive unit 66 that drives the brushless motor 20 (see FIG. 2), and a motor. The motor control unit 71 controls the drive unit 66, and a plurality of anti-noise elements 80 that suppress noise of current supplied from an external power source.
In the following description, the outer surface of the bus bar unit main body 53 opposite to the motor case 11 is referred to as a first main surface 51, and the opposite side of the first main surface 51, that is, the surface on the motor case 11 side. Will be described as the second main surface 52.

(Bus bar unit body)
FIG. 6 is a plan view when the bus bar unit main body is viewed from the second main surface side, and FIG. 7 is a longitudinal sectional view of the bus bar unit main body.
As shown in FIGS. 6 and 7, the bus bar unit main body 53 has a resin mold body 153 made of a substantially plate-like insulating material, and a plurality of bus bars 100 are embedded in the resin mold body 153. At the same time, a connector part 58 into which a connector (not shown) extending from an external device can be fitted is integrally formed with the resin mold body 153. The connector part 58 is erected along the same direction as the central axis O (see FIG. 2).
The bus bars 100 embedded in the bus bar unit main body 53 are arranged side by side without crossing each other. For this reason, it is comprised so that generation | occurrence | production of the noise by crosstalk may be suppressed.

The plurality of bus bars 100 mainly include signal system terminal bus bars 101a to 101d, power terminal bus bars 102a and 102b, power bus bars 103a and 103b, and three-phase bus bars 104a to 104c. The metal plate material is bent into a desired shape.
The resin mold body 153 includes a primary molding portion 154 embedded in the connector portion 58 and a secondary molding portion 155 that covers the primary molding portion 154.

8 is a perspective view of the bus bar unit body through the secondary molding portion, FIG. 9 is a perspective view of the primary molding portion, and FIG. 10 is a plan view of the primary molding portion.
As shown in FIGS. 5 to 10, the primary molding portion 154 is erected on the substantially rectangular parallelepiped primary connector main body portion 156 constituting the connector portion 58 and the distal end surface 156 a of the primary connector main body portion 156. Three partition plate portions 157a, 157b, and 157c and a flange portion 158 formed at the base end of the primary connector main body portion 156 are integrally formed.

The primary connector main body 156 is arranged in a substantially rectangular shape in plan view so that the block 156b that constitutes the majority of the primary connector main body 156 is disposed at the tip of the block 156b and its outer shape is slightly smaller than the block 156b. The formed plate-like portion 156c is integrally formed. The end surface of the plate-like portion 156c is used as the front end surface 156a of the primary connector main body portion 156.
Further, the primary connector main body 156 has a plurality of thinned portions 156d recessed along the height direction. These thinned portions 156d are formed so that the flange portion 158 side opens and does not penetrate the primary connector main body portion 156 in the height direction.

  It should be noted that the depth H1 of the thinned portion 156d can be arbitrarily set in consideration of the hot water flow of the resin. That is, the interval between the leading end of the thinned portion 156d and the leading end surface 156a of the primary connector main body 156 is set to such an extent that the resin can flow in hot water and does not cause sink marks. More specifically, it is preferable to set the interval between the leading end of the thinned portion 156d and the leading end surface 156a of the primary connector main body 156 to about 2 mm.

  The three partition plate portions 157a, 157b, and 157c erected on the distal end surface 156a of the primary connector main body portion 156 are arranged in parallel along the thickness direction of the partition plate portions 157a, 157b, and 157c, respectively. Of the three partition plate portions 157a, 157b, and 157c, on the inner side surfaces of the two partition plate portions 157a and 157c arranged on both outer sides, a protruding strip portion 159 is provided on one end side in the short side direction, respectively. It is formed along.

  On the other hand, the flange portion 158 formed at the base end of the primary connector main body portion 156 extends along the parallel direction of the three partition plate portions 157a, 157b, and 157c erected on the distal end surface 156a of the primary connector main body portion 156. It is formed in a substantially rectangular plate shape in plan view so as to be long. On one side 158a in the short direction of the flange portion 158, important notches 160a and 160a are formed at two corners at both ends in the longitudinal direction. Further, on the other side 158b in the short side direction of the flange portion 158, small notches 160b and 160b are formed at two corners at both ends in the longitudinal direction.

  In the primary molding part 154 formed in this way, signal system terminal bus bars 101a to 101d and power terminal bus bars 102a and 102b are embedded. That is, the signal system terminal bus bars 101 a to 101 d and the power terminal bus bars 102 a and 102 b correspond to a first terminal group integrated by the primary molding unit 154.

FIG. 11 is a perspective view of the signal system terminal bus bar and the power terminal bus bar.
As shown in FIGS. 8 to 11, the signal system terminal bus bars 101 a to 101 d are formed by bending a metal plate so as to extend along the primary connector main body 156 and the flange 158. The signal system terminal bus bars 101a to 101d include a connector side end portion 110a protruding from the front end surface 156a of the primary connector main body 156, a control unit side end portion 110b protruding from the other side 158b of the flange portion 158, and It has a bridge portion 110c that is provided so as to straddle the end portions 110a and 110b and connects the two end portions 110a and 110b.

The connector side end portions 110a of the signal system terminal bus bars 101a to 101d are disposed outside the two partition plate portions 157a and 157c disposed on both outer sides of the three partition plate portions 157a, 157b and 157c. Yes.
Further, the control unit side end portion 110b of the signal system terminal bus bars 101a to 101d is formed to bend in the same direction as the protruding direction of the connector side end portion 110a after protruding from the other side 158b of the flange portion 158.

  The power terminal bus bars 102a and 102b are also formed by bending a metal plate so as to extend along the primary connector main body 156 and the flange 158. The power terminal bus bars 102a and 102b include a connector-side end portion 111a protruding from the front end surface 156a of the primary connector body 156, a control unit-side end portion 111b protruding from the other side 158b of the flange portion 158, and these It is provided so as to straddle the end portions 111a and 111b, and has crossing portions 111c and 111d that connect the two end portions 111a and 111b.

Of the two power terminal bus bars 102a and 102b, the connecting portion 111c of the power terminal bus bar 102a is formed in a substantially U shape in plan view so as to bypass the connector side end portion 110a of the signal system terminal bus bars 101a and 101b. Has been. A noise prevention element connecting portion 111e is integrally formed at the base end of the control unit side end portion 111b of the power terminal bus bar 102a.
On the other hand, of the two power terminal bus bars 102a and 102b, the power terminal bus bar 102b is integrally formed with a sub-crossover portion 111f at the base end of the connector side end portion 111a separately from the crossover portion 111d. The sub-crossing portion 111f is formed in a substantially U-shape in plan view so as to bypass the connector side end portion 110a of the signal system terminal bus bars 101a and 101b, and a noise prevention element connecting portion 111e is integrally formed at the tip thereof. Has been.

The connector side end portions 111a of the power terminal bus bars 102a and 102b are disposed between the partition plate portions 157a, 157b and 157c. By arranging in this way, it is possible to ensure insulation between the connector-side end portions 111a of the power terminal bus bars 102a and 102b and the connector-side end portions 110a of the signal system terminal bus bars 101a to 101d.
Further, the noise prevention element connecting portion 111e of the power terminal bus bars 102a and 102b protrudes from the other side 158b of the flange portion 158. Further, the control unit side ends 111b of the power terminal bus bars 102a and 102b are formed so as to bend in the same direction as the protruding direction of the connector side end 111a after protruding from the other side 158b of the flange 158.

  Here, the transition part 110c of the signal system terminal bus bars 101a to 101d, the transition part 111c of the power terminal bus bar 102a, and the auxiliary transition part 111f of the power terminal bus bar 102b are provided in the lightening part 156d of the primary connector main body part 156. Bending portions 112 and 113 are respectively formed at portions corresponding to. These bent raised portions 112 and 113 are formed so that the thickness direction is substantially orthogonal to the extending direction of the thinned portion 156d. In other words, the width direction of the bent raised portions 112 and 113 is the same as the extending direction of the thinned portion 156d.

  By forming in this way, as shown in detail in FIG. 10, compared to the case where the bent raised portions 112 and 113 are formed so that the thickness direction thereof is along the extending direction of the thinned portion 156d. , The gap K1 between the bent raised portions 112 and 113 can be widened. For this reason, it is possible to form a plurality of lightening portions 156d without increasing the size of the primary connector main body portion 156.

  Returning to FIGS. 5 to 8, the secondary molding portion 155 has a secondary connector main body 161 that is formed so as to cover the primary connector main body 156 and constitutes the appearance of the connector portion 58. The secondary connector main body 161 is formed in a cylindrical shape so as to extend in the standing direction of the partition plate portions 157a to 157c of the primary molding portion 154 and surround the periphery of the partition plate portions 157a to 157c. The peripheral wall 162 is integrally formed. The peripheral wall portion 162 constitutes a peripheral wall of the connector portion 58, and a connector (none of which is not shown) extending from an external device can be fitted into the connector portion 58 by the peripheral wall portion 162.

  Further, a plate-like base portion 163 having a substantially rectangular shape in plan view is integrally formed at the base end of the secondary connector main body portion 161 on the opposite side to the peripheral wall portion 162. The base portion 163 extends in a direction orthogonal to the central axis O (see FIG. 2), that is, a direction orthogonal to the standing direction of the connector portion 58. The outer surface of the base portion 163 opposite to the motor case 11, that is, the surface opposite to the side on which the connector portion 58 is erected is defined as the first main surface 51. A surface opposite to the main surface 51 is a second main surface 52.

The base portion 163 covers the flange portion 158 of the primary molding portion 154 from the seal portion 164 formed at the proximal end of the connector portion 58 and the side corresponding to the other side 158b of the flange portion 158 in the seal portion 164. The base body 165 extends so as to be substantially orthogonal to the standing direction of the connector portion 58.
The seal portion 164 has a flat surface 164a that is orthogonal to the central axis O (see FIG. 2) on the second main surface 52 side. The flat surface 164a serves as the bus bar unit main body 53 and the motor case 11.
This is configured as a sealing surface for sealing between the flange portion 42.

The seal surface will be described more specifically.
Here, as shown in FIGS. 2 and 3, the connector portion 58 is led out of the housing 10 through the through hole 43 of the flange portion 42 when the control device 50 is attached to the control device arrangement portion 40. It is like that. In this state, a seal member 56 that is annularly arranged around the connector portion 58 is sandwiched between the flat surface 164 a of the bus bar unit main body 53 and the flange portion 42 of the housing 10.

  The seal member 56 is an annular O-ring. The seal member 56 is fitted into a ring groove 44 formed so as to surround the through hole 43 of the flange portion 42, and is slightly crushed by the flat surface 164 a of the bus bar unit main body 53. Thereby, the sealing member 56 ensures the sealing performance around the connector portion 58, and water that has entered from the gap between the connector portion 58 and the through hole 43 of the flange portion 42 moves to the outside of the sealing member 56. Is preventing.

  Here, as shown in detail in FIG. 7, since the primary molding portion 154 is embedded in the secondary connector main body 161 and the seal portion 164, the wall thickness T <b> 1 of the secondary connector main body 161, the peripheral wall portion The wall thickness T2 of 162 and the wall thickness T3 of the seal portion 164 are set substantially equal. It is desirable to set these wall thicknesses T1 to T3 to about 2 mm. By setting in this way, it is possible to minimize the occurrence of sink marks without inhibiting the hot water flow of the resin. In the seal portion 164, the flatness of the flat surface 164a can be increased.

  Returning to FIGS. 5 to 8, the base body 165 has a distal end portion 165 a opposite to the connector portion 58 radially outside the position corresponding to the power supply terminals 29 a to 29 c (see FIG. 3) of the bus burring unit 28. It is formed so as to extend toward. The wall thickness T4 of the base body 165 is also set to be approximately equal to the wall thickness T1 of the secondary connector body 161, the wall thickness T2 of the peripheral wall 162, and the wall thickness T3 of the seal portion 164.

  As shown in detail in FIG. 6, first bus bar openings 54 a penetrating in the thickness direction are formed at positions corresponding to the power supply terminals 29 a to 29 c of the base body 165. Further, a second bus bar opening 54b penetrating in the thickness direction is formed closer to one side in the lateral direction than the first bus bar opening 54a. Further, a third bus bar opening 54c penetrating in the thickness direction is formed on the seal portion 164 side of the base body 165.

Then, the control unit side end portion 110b of the signal system terminal bus bars 101a to 101d and the power terminal bus bars 102a and 102b are controlled from the second main surface 52 closer to the seal portion 164 than the third bus bar opening 54c of the base body 165. The unit side end 111b is in a protruding state.
In addition, as shown in detail in FIG. 6, a plurality of lightening portions 165 b are formed on the distal end portion 165 a side of the base body 165. Thereby, the wall thickness of the whole base main body 165 is set substantially uniform.

  Further, as shown in detail in FIG. 8, power bus bars 103 a and 103 b and three-phase bus bars 104 a to 104 c are embedded in the base body 165. That is, the power bus bars 103 a and 103 b and the three-phase bus bars 104 a to 104 c correspond to a second terminal group integrated by the secondary molding portion 155.

  The power bus bars 103a and 103b include a power bus bar main body 114a formed on a large part of the base main body 165, a control unit side end 114b extending from the power bus bar main body 114a toward the connector portion 58, and a noise prevention. The element connection portion 114c, the tongue piece portion 114d, and the motor drive unit side end portion 114e extending from the power bus bar main body 114a toward the opposite side of the connector portion 58 are integrally formed.

The control unit side end 114b extends from the third bus bar opening 54c of the base body 165 to the seal portion 164 side, and then the control unit side end 110b of the signal system terminal bus bars 101a to 101d and the power terminal bus bar 102a. , 102b are bent so as to protrude from the position corresponding to the control unit side end portion 111b toward the second main surface 52 side of the base body 165.
The motor drive unit side end portion 114 e extends to the tip end portion 165 a side slightly from the second bus bar opening 54 b of the base body 165.

The three-phase bus bars 104a to 104c have a substantially L-shaped cross section, the base end 115a is exposed through the second bus bar opening 54b of the base body 165, and the tip 115b is the first bus bar opening. It is formed so as to protrude toward the first main surface 51 through 54a.
It should be noted that the positions in the thickness direction of the power bus bars 103a and 103b embedded in the base body 165 specify the positions of the power bus bars 103a and 103b that can reduce the warping of the base body 165. , That position is set. Specifically, with respect to the thickness T4 of the base body 165, the plate thickness of the power bus bars 103a and 103b is Tm, and the distance from the first main surface 51 of the base body 165 to the power bus bars 103a and 103b is Tb1, When the distance from the second main surface 51 of the base body 165 to the power bus bars 103a, 103b is Tb2,
T4 = Tb1 + Tb2 + Tm (Tb1≈Tb2)
It is set to become.

4 to 6, the power terminal bus bars 102a and 102b and the power bus bars 103a and 103b are connected to the external power source and the motor via the noise prevention element 80 (see FIG. 5). The drive unit 66 is electrically connected. The motor control unit 71 is electrically connected to the control unit side end 114b of the power bus bars 103a and 103b.
Furthermore, the base ends 115a of the three-phase bus bars 104a to 104c are electrically connected to the motor drive unit 66, while the leading ends 115b of the three-phase bus bars 104a to 104c are connected to the power supply terminals 29a to 29c of the bus burring unit 28. Electrically connected.

  In addition, pipe-shaped collar members 57a to 57d made of a metal material are insert-molded at the four corners of the base body 165 of the bus bar unit body 53. As shown in FIG. 3, the bus bar unit main body 53 has an axial opening in the motor case 11 by inserting bolts 116 into the respective collar members 57 a to 57 d and fastening them to the control device disposing portion 40. It is integrally connected to the end on the 12 side.

Here, as shown in FIG. 6, among the color members 57 a to 57 d, the color members 57 a and 57 b provided on the connector portion side are provided symmetrically with the connector portion 58 in between, and around the connector portion 58. Evenly arranged. Therefore, as shown in FIG. 3, when the bolts 116 are respectively inserted into the collar members 57 a and 57 b and fastened to the control device disposing portion 40, a fastening load is evenly generated around the connector portion 58.
As a result, the seal member 56 arranged in an annular shape around the connector portion 58 is crushed substantially uniformly over the entire circumference by the flange portion 42 of the housing 10 and the flat surface 164 a of the bus bar unit main body 53. Therefore, high sealing performance can be secured over the entire circumference around the connector portion 58.
Further, among the color members 57a to 57d, a flat surface formed between the color members 57c and 57d provided on the motor drive unit 66 side at the same height as the surface on which the color members 57c and 57d are disposed. A surface 51b is formed.
Note that the collar members 57a to 57d may be disposed on the inner side of the region connecting the four color members 57a to 57d shown in FIG. Also by this, the fastening load of the bolt 116 can be generated substantially uniformly and high sealing performance can be ensured.

  As shown in FIG. 5, the motor drive unit 66 is located in a region corresponding to the disposition opening 41 (see FIG. 3) of the control device disposition portion 40 on the first main surface 51 of the base body 165. It is attached by a tapping screw 66a. The motor drive unit 66 is formed in a substantially rectangular shape in plan view, and includes, for example, a switching element such as a field effect transistor (FET) or an insulated gate bipolar transistor (IGBT). Built in.

  A terminal row 67 is provided on one side surface of the motor drive unit 66 on the first bus bar opening 54a side. Some terminals constituting the terminal row 67 are formed in a substantially L shape, and are directed from the first main surface 51 side of the base body 165 toward the second main surface 52 side via the plurality of through holes 54d. It penetrates and protrudes from the second main surface 52.

  Further, the three three-phase terminals 67a, 67b, 67c and the two power terminals 67d, 67e constituting the terminal row 67 are formed in a crank shape in cross section. Three three-phase terminals 67a, 67b, and 67c are connected to the base ends 115a of the three-phase bus bars 104a to 104c exposed through the second bus bar opening 54b. Further, two power terminals 67d and 67e are connected to the motor drive unit side end portion 114e of the power bus bars 103a and 103b exposed through the second bus bar opening 54b.

The motor drive unit 66 converts the DC power input from the power terminals 67d and 67e into a three-phase AC and outputs it from the three-phase terminals 67a, 67b and 67c in a desired energization pattern.
A heat dissipation sheet 68 made of, for example, silicone rubber is attached to the outer surface of the motor drive unit 66.

  As shown in FIGS. 4, 6, and 8, the second main surface 52 of the base main body 165 has an area corresponding to the opening 41 (see FIG. 3) of the control device disposing portion 40. A recessed portion 52a is formed. A motor control unit 71 is disposed at a position corresponding to the recess 52a. The motor control unit 71 is formed by mounting electronic elements (not shown) on a substantially rectangular plate-like multilayer substrate 72 in which wiring is printed on glass epoxy, for example.

  The multilayer substrate 72 includes control unit side ends 110b of signal system terminal bus bars 101a to 101d (see FIG. 6) erected from the second main surface 52, and control units of power bus bars 103a and 103b (see FIG. 6). A plurality of through holes 72b through which the side end portion 114b and the end portion 67A of the terminal row 67 of the motor drive unit 66 are inserted are formed.

  Further, as shown in FIG. 5, a dead space is formed on the first main surface 51 on the opposite side of the connector portion 58 across the base body 165, and a plurality of parts constituting the control device 50 are formed in this part. A noise prevention element 80 is provided. Each noise prevention element 80 includes, for example, an X capacitor 87, smoothing capacitors 88 and 88, and a choke coil 81. The X capacitor 87, the smoothing capacitors 88 and 88, and the choke coil 81 are accommodated in the anti-noise element accommodating portions 60a to 60d formed in a substantially bathtub shape on the first main surface 51, respectively.

  The X capacitor 87 is provided mainly for suppressing radio noise. The X capacitor 87 is, for example, a substantially cylindrical electric field capacitor, and is provided between the power terminal bus bars 102a and 102b (see FIG. 6). The X capacitor 87 is arranged such that the central axis thereof is along the longitudinal direction of the base body 165.

  In the X capacitor 87, a pair of lead portions 87a and 87b extend substantially in parallel from the end surface on the motor drive unit 66 side. The pair of lead portions 87a and 87b are formed in a substantially crank shape. The tips of the pair of lead portions 87a and 87b are disposed in the third bus bar opening 54c, and the anti-noise element connecting portion 111e of the power terminal bus bars 102a and 102b on the positive electrode side, for example, by projection welding (see FIG. 11). Connected to.

  The smoothing capacitor 88 is provided to suppress a change in voltage caused by driving the brushless motor 20 (see FIG. 2). Similar to the X capacitor 87, the smoothing capacitors 88 are, for example, cylindrical electric field capacitors, and a pair of smoothing capacitors 88 are provided between the power bus bars 103a and 103b. As with the X capacitor 87, the smoothing capacitor 88 is arranged so that its central axis is along the longitudinal direction of the base body 165.

  A pair of lead portions 88a and 88b extend substantially in parallel from the end surface of the smoothing capacitor 88 on the motor drive unit 66 side. The pair of lead portions 88a and 88b are formed in a substantially crank shape. The tips of the pair of lead portions 88a and 88b are disposed in the third bus bar opening 54c, and for example, by projection welding or the like, the control unit side end portion 114b and the tongue piece portion 114d (see FIG. 8) of the power bus bars 103a and 103b. ).

  The choke coil 81 is provided mainly for suppressing radio noise. The choke coil 81 is formed by winding a conducting wire 83 around a cylindrical core 82 made of a magnetic material such as ferrite, for example, and the anti-noise element connecting portion 111e of the power terminal bus bar 102a on the positive side and the power bus bar 103a. The anti-noise element connecting portion 114c (see FIG. 8). In the core 82, the side of the motor drive unit 66 is the winding start side of the conducting wire 83, and the side opposite to the motor driving unit 66 is the winding end side of the conducting wire 83.

  The conducting wire 83 of the choke coil 81 extends substantially in parallel toward the motor drive unit 66 such that one end 83a and the other end 83b are along the central axis of the core 82, respectively. One end portion 83a and the other end portion 83b of the conducting wire 83 are formed in a substantially crank shape, and are disposed in the third bus bar opening 54c. For example, the anti-noise element connecting portion of the power terminal bus bar 102a by projection welding or the like. 111e and the noise prevention element connecting portion 114c of the power bus bar 103a (both are shown in FIG. 8).

  By the way, when forming the choke coil 81, the conducting wire 83 is wound around the core 82 from the one end 83a side. The other end portion 83 b of the conducting wire 83 is bent at the winding end side of the core 82, and is drawn out to the motor drive unit 66 side (the winding start side of the core 82) opposite to the winding end side of the core 82. . At this time, since the conducting wire 83 is wound in a coil shape, a springback acts on the other end portion 83 b of the conducting wire 83 in a direction away from the one end portion 83 a of the conducting wire 83. As a result, deviation occurs in the positions of the one end 83a and the other end 83b of the conducting wire 83 of the choke coil 81, and it is difficult to accurately weld the conducting wire 83 to the power terminal bus bar 102a and the power bus bar 103a. There is a risk.

  Therefore, a pair of guides is provided between the third bus bar opening 54c and the noise prevention element storage portion 60d so as to extend in the extending direction of the power terminal bus bar 102a and the power bus bar 103a in the third bus bar opening 54c. Grooves 61 and 61 are provided. The pair of guide grooves 61, 61 are formed by standing a pair of walls 61a, 61a, respectively.

  One end 83a and the other end 83b of the conducting wire 83 can be arranged in the pair of guide grooves 61, 61, respectively. Since the one end 83a and the other end 83b of the conducting wire 83 are positioned in the pair of guide grooves 61 and 61, respectively, the choke coil 81 is positioned relative to the power terminal bus bar 102a and the power bus bar 103a. The conducting wire 83 can be easily and accurately welded.

(Cover member)
As shown in FIG. 3, the cover member 46 is fastened and fixed to the control device arrangement portion 40 by, for example, bolts 117, and covers the control device arrangement portion 40 and the control device 50 from the outside in the axial direction. Yes.
The cover member 46 is made of a metal material such as iron (carbon steel), aluminum, or copper. In particular, the cover member 46 is preferably formed of aluminum having high thermal conductivity, light weight, and low cost.

  The cover member 46 is formed in a substantially bathtub shape by a peripheral wall 47 disposed in a rectangular frame around the central axis O corresponding to the control device disposing portion 40 and a bottom wall 48 facing in the axial direction. . Between the peripheral wall 47 of the cover member 46 and the control device disposing portion 40, an O-ring 99 is disposed over the entire circumference in the circumferential direction. The O-ring 99 is fitted into a ring groove 47a formed on the front end surface of the peripheral wall 47 of the cover member 46, and exhibits a sealing property by being slightly crushed when the cover member 46 is fastened by the bolt 117. Thereby, the sealing property between the control apparatus arrangement | positioning part 40 and the cover member 46 is ensured.

  The bottom wall 48 of the cover member 46 is provided with a breathing hole 45 that communicates the inside and outside of the housing 10. The breathing hole 45 is for releasing the pressure to the outside of the housing 10 when the inside of the housing 10 becomes a pressure higher than the outside of the housing 10 due to, for example, expansion of air accompanying a temperature rise. In addition, the breathing hole 45 is provided at a position facing the flat surface 51b of the first main surface 51 of the control device 50 so as to avoid an obstacle that hinders the breathing function, thereby allowing gas to flow into the control device 50. It has come to be smooth.

A plurality of cooling fins 49 are integrally formed on the outer surface of the bottom wall 48 of the cover member 46. The cooling fins 49 radiate heat generated by the control device 50.
Here, as shown in FIG. 2, the motor drive unit 66 attached to the first main surface 51 side of the control device 50 contacts the inner side surface 48 a of the bottom wall 48 of the cover member 46 via the heat radiation sheet 68. It is supposed to be. Thus, the motor drive unit 66 can dissipate heat from the cooling fins 49 of the cover member 46 efficiently by transferring heat to the cover member 46 via the heat dissipation sheet 68.
Further, since the cover member 46 is fastened and fixed to the control device arrangement portion 40 of the housing 10, the heat generated by the control device 50 is radiated through the cooling fins 49 of the cover member 46 and the cover member 46. Compared with the above, the volume is large, and the aluminum housing 10 having a high thermal conductivity is also drawn by heat and diffused, so that the cooling performance of the control device 50 can be further enhanced.

(Bus bar unit body manufacturing method)
Next, based on FIG. 12, FIG. 13, the manufacturing method of the bus-bar unit main body 53 is demonstrated.
FIG. 12 is an explanatory diagram of the manufacturing process of the bus bar unit main body, and (a) to (f) show each process. FIG. 13 is a flowchart of the manufacturing process of the bus bar unit main body.
First, as shown in FIG. 13, the primary molding part 154 is molded (primary molding process, ST100). In the primary molding process, first, as shown in FIGS. 12 (a) and 13, a signal system terminal bus bars 101a to 101d and a power are used in a mold (not shown) for molding the primary molding part 154. Terminal bus bars 102a and 102b are set (ST101 in FIG. 13).

At this time, the signal system terminal bus bars 101a to 101d are in a state in which the control unit side end portions 110b are connected to each other by a control unit side connecting portion 105 having a substantially E shape in plan view. Further, the noise prevention element connecting portions 111e of the power terminal bus bars 102a and 102b are connected to each other by a connection side connecting portion 106 having a substantially U-shape in plan view.
As described above, the plurality of signal system terminal bus bars 101 a to 101 d are integrated by the control unit side connecting portion 105, and the two power terminal bus bars 102 a and 102 b are integrated by the connecting side connecting portion 106. For this reason, each terminal bus-bar 101a-101d, 102a, 102b can be easily set to the metal mold | die not shown.

In this state, as shown in FIGS. 12B and 13, a resin is poured into a mold (not shown) to form a primary molding portion 154 (ST102 in FIG. 13).
As shown in detail in FIG. 10, the gate position GP0 when the primary molding portion 154 is molded is a substantially central portion on the flange portion end surface 158c side opposite to the connector main body portion 156 of the flange portion 158. The signal system bus bars 101a to 101d and the power terminal bus bars 102a and 102b inserted therein are set at positions that do not overlap in the axial direction. By setting the gate position GP0 in this way, the pressure of the injected resin is not directly applied to each of the bus bars 101a to 101d, 102a, and 102b when the primary molding portion 154 is molded, and a short shot is performed. The primary molded portion 154 can be molded while preventing the above.
Here, in the primary connector main body portion 156 of the primary molding portion 154, since a plurality of thinned portions 156d are recessed along the height direction, the thickness of the entire primary molding portion 154 is substantially equal. It is set uniformly. For this reason, generation | occurrence | production of the sink of the primary shaping | molding part 154 can be suppressed to the minimum.

  Also, each control unit side end 110b of the signal system terminal bus bars 101a to 101d, the control unit side end 111b of the power terminal bus bar 102a, and the control unit side end 111b and one end of the power terminal bus bar 102b are respectively It protrudes from the other side 158b of the flange portion 158 constituting the primary molded portion 154. For this reason, the control unit side coupling portion 105 and the connection side coupling portion 106 are exposed to the outside of the primary molding portion 154.

  Under such a configuration, subsequently, as shown in FIGS. 12 (c) and 13, the control unit side connecting portion 105 is cut from the signal system terminal bus bars 101a to 101d, and the power terminal bus bars 102a and 102b. The connection side connecting part 106 is cut off from. Then, the terminal bus bars 101a to 101d, 102a, and 102b are separated from each other (primary separation step, ST103 in FIG. 13). Thereby, the primary molding process is completed.

  Subsequently, as shown in FIG. 13, the secondary molding portion 155 is molded (secondary molding step, ST200). In the secondary molding step, first, as shown in FIGS. 12D and 13, a primary molding portion molded in the primary molding step on a mold (not shown) for molding the secondary molding portion 155. 154 is set, and power bus bars 103a and 103b, three-phase bus bars 104a to 104c, and color members 57a to 57d are set (ST201 in FIG. 13).

Here, the flange portion 158 formed at the base end of the primary connector main body portion 156 has important notches 160a and 160a formed on one side 158a in the short direction, so that the collar members 57a and 57b Placement is not hindered.
Further, the control unit side end portions 114b of the power bus bars 103a and 103b are connected to each other by the control unit side connection portion 107, and the control unit side end portion 114b of the power bus bar 103a and the tongue of the power bus bar 103b. The portion 114d is connected to the control unit side connecting portion 107. Furthermore, the motor drive unit side ends 114e of the power bus bars 103a and 103b and the base ends 115a of the three-phase bus bars 104a to 104c are connected by the drive unit side connecting portion 108.

  In this way, the two power bus bars 103a and 103b are integrated by the control unit side connecting portion 107, and the three three-phase bus bars 104a to 104a are added to the power bus bars 103a and 103b by the drive unit side connecting portion 108. 104c is integrated. For this reason, each bus-bar 103a, 103b, 104a-104c can be easily set to the metal mold | die not shown.

In this state, as shown in FIGS. 12 (e) and 13, a resin is poured into a mold (not shown) to form a secondary molding portion 155 (ST202 in FIG. 13).
As shown in detail in FIG. 5, the gate positions GP <b> 1 to GP <b> 3 when forming the secondary forming portion 155 are set at one point on the seal portion 164 on the first main surface 51 side of the base portion 163, and on the base body 165. Two points in total are set. The gate position GP1 of the seal portion 164 is disposed on the opposite side of the base body 165 with respect to the noise prevention element storage portions 60a to 60d. The gate positions GP2 and GP3 of the base main body 165 are disposed on both sides in the short direction of the base main body 165 and slightly closer to the tip end portion 165a than the approximate center in the longitudinal direction. Thus, by setting the gate positions GP1 to GP3, it is possible to prevent warpage and short shots when the secondary forming portion 155 is formed.

Here, the overall thickness of the connector part 58 is thicker than that of the base part 163, but the primary molding part 154 is formed in advance, and the secondary molding so that the primary molding part 154 is insert-molded. Since the molded portion 155 is formed, the thickness T1 of the secondary connector main body portion 161, the thickness T2 of the peripheral wall portion 162, the thickness T3 of the seal portion 164, and the thickness T4 of the base main body 165 are substantially the same. It has a thickness (for example, about 2 mm).
The control unit side connecting portion 107 is exposed to the outside through the third bus bar opening 54c of the base body 165, and the drive unit side connecting portion 108 is connected to the base body 165 through the second bus bar opening 54b. Exposed outside.

  Under such a configuration, subsequently, as shown in FIGS. 12 (f) and 13, the control unit side connecting portion 107 and the drive unit side connecting portion are respectively connected from the power bus bars 103a and 103b and the three-phase bus bars 104a to 104c. The part 108 is cut off. Then, power bus bars 103a and 103b and three-phase bus bars 104a to 104c are separated (secondary separation step, ST203 in FIG. 13). Thereby, the secondary molding process is completed, and the manufacture of the bus bar unit main body 53 is completed.

(effect)
Therefore, according to the above-described embodiment, the resin molded body 153 of the bus bar unit main body 53 is formed by the primary molding portion 154 embedded in the connector portion 58 and the secondary molding portion 155 that covers the primary molding portion 154. After forming the primary molding part 154, since the secondary molding part 155 is formed so as to insert-mold the primary molding part 154, the thickness when forming the molding parts 154, 155 is increased. In general, it can be set almost uniformly. In this way, thickness unevenness when forming the molding parts 154 and 155 can be eliminated, so that the occurrence of sink marks at the time of molding a portion requiring strength such as the connector part 58 can be suppressed to a minimum. Can do. For this reason, the molding accuracy of the bus bar unit main body 53 can be improved.

In addition, since it is not necessary to steal meat more than necessary in places where the strength is required, such as the connector portion 58, the strength of the connector portion 58 can be improved.
Further, since it is not necessary to increase the thickness of the entire resin mold body 153 in accordance with the thickness of the portion where strength is required in order to eliminate the thickness unevenness, the bus bar unit main body 53 can be reduced in size.

  Then, the transition part 110c of the signal system terminal bus bars 101a to 101d, the transition part 111c of the power terminal bus bar 102a, and the auxiliary transition part 111f of the power terminal bus bar 102b are connected to the lightening part 156d of the primary connector main body part 156. Bending portions 112 and 113 are formed at the corresponding portions, respectively. For this reason, it is possible to secure a space for forming the plurality of lightening portions 156d at locations where the bent raised portions 112 and 113 are formed. Therefore, the thickness of the entire primary connector body 156 can be made uniform without increasing the size of the primary connector body 156. As a result, the molding accuracy of the bus bar unit main body 53 can be further improved.

Further, when performing the primary molding process, the signal unit terminal bus bars 101a to 101d are integrated in advance by the control unit side connecting portion 105, and the two power terminal bus bars 102a and 102b are integrated by the connecting side connecting portion 106. Are integrated. For this reason, each terminal bus bar 101a-101d, 102a, 102b can be easily set to the metal mold | die (not shown) which shape | molds the primary shaping | molding part 154. FIG. Therefore, the work of the primary molding process can be simplified.
Furthermore, since the control unit side coupling part 105 and the connection side coupling part 106 are exposed outside the primary molding part 154, the terminal bus bars 101a to 101d, 102a, 102b are formed after the primary molding part 154 is molded. It can be reliably separated.

  When performing the secondary forming step, the two power bus bars 103a and 103b are integrated in advance by the control unit side connecting portion 107, and the power bus bars 103a and 103b and the three power bus bars 103a and 103b are integrated by the drive unit side connecting portion The three-phase bus bars 104a to 104c are integrated. For this reason, each bus-bar 103a, 103b, 104a-104c can be easily set to the metal mold | die not shown. Therefore, the work of the secondary molding process can be simplified.

Further, the control unit side connecting portion 107 is exposed to the outside through the third bus bar opening 54c of the base body 165, and the drive unit side connecting portion 108 is connected through the second bus bar opening 54b of the base body 165. Exposed outside. For this reason, the power bus bars 103a and 103b and the three-phase bus bars 104a to 104c can be reliably separated.
As described above, since the connecting portions 107 and 108 are exposed to the outside through the openings 54b and 54c, almost all of the power bus bars 103a and 103b and the three-phase bus bars 104a to 104c are embedded in the base body 165. In this state, the power bus bars 103a and 103b and the three-phase bus bars 104a to 104c can be separated. For this reason, the insulation of the bus-bar unit main body 53 can be improved.

Further, the bus bar unit main body 53 is formed so that the base portion 163 of the resin mold body 153 and the connector portion 58 are substantially orthogonal to each other, and around the base end of the secondary connector main body portion 161 in the secondary molding portion 155. A flat surface 164a is formed. The flat surface 164 a is configured as a seal surface for sealing between the bus bar unit main body 53 and the flange portion 42 of the motor case 11.
Here, by forming the seal part 164 of the secondary molding part 155 on the flange part 158 of the primary molding part 154, the thickness when molding the seal part 164 is optimal for increasing the flatness. The thickness can be set (for example, about 2 mm). Thus, since the flat surface 164a with high flatness is configured as the seal surface, the sealability between the bus bar unit main body 53 and the flange portion 42 of the motor case 11 can be improved.

The present invention is not limited to the above-described embodiment, and includes various modifications made to the above-described embodiment without departing from the spirit of the present invention.
For example, in the above-described embodiment, the case where the pump unit 90 of the electric pump 1 is a so-called trochoid pump has been described. However, the present invention is not limited to this. For example, a non-volume regenerative pump having an impeller may be used.

  In addition, the materials, shapes, and the like of the housing 10, the brushless motor 20, the control device 50, the anti-noise element 80, the pump unit 90, the bus bar 100, and the like are not limited to the embodiments. For example, the bus bar 100 may be formed of aluminum. Further, the housing 10 may be formed of a metal material such as iron (carbon steel).

  Further, the case where the suction port 16 and the discharge port 17 are formed inside the bottom portion 13 of the motor case 11 has been described. However, the suction port 16 and the discharge port 17 may be provided on the pump unit 90 side without being provided on the motor case 11 side. Specifically, the suction port 16 and the discharge port 17 may be formed in the pump cover 94 that covers the pump case 91.

1 Electric pump 2 Brushless motor (electric motor)
10 Housing (motor housing, fixed member)
11 Motor case (motor housing, fixed member)
21 Stator 31 Rotor 42 Flange 53 Busbar unit main body 54a First busbar opening 54b Second busbar opening (opening)
54c Third bus bar opening (opening)
58 Connector 90 Pump 100 Bus bar (terminal)
101a, 101b, 101c, 101d Signal system terminal bus bar (terminal, first terminal group)
102a, 102b Power terminal bus bar (terminal, first terminal group)
103a, 103b Bus bar for power (terminal, second terminal group)
104a, 104b, 104c Three-phase bus bar (terminal, second terminal group)
105 Control unit side connecting part (first connecting part)
106 Connection side connecting part (first connecting part)
107 Control unit side connecting part (second connecting part)
108 Drive unit side connecting part (second connecting part)
110a Connector side end (connector terminal)
110b Control unit side end portion 110c Transition portion 111a Connector side end portion (connector terminal)
111b Control unit side end portions 111c, 111d Crossover portion 111e Anti-noise element connection portion 111f Sub-crossover portion 153 Resin molded body (resin body)
154 Primary molded portion 155 Secondary molded portion 158 Flange portion 161 Secondary connector main body (connector main body)
162 Peripheral wall portion 163 Base portion 164 Seal portion 164a Flat surface 165 Base body (base portion)

Claims (14)

A resin molded product for an electric motor in which a first terminal group and a second terminal group composed of a plurality of terminals are embedded in a resin body, and a connector portion into which a connector extending from an external device can be fitted is integrally formed. And
The resin body is
A primary molding unit that integrates the first terminal group and causes one end of the first terminal group to function as a connector terminal protruding into the connector unit;
The primary molded part is composed of a secondary molded part for insert molding,
The secondary molded part is
A peripheral wall part forming a peripheral wall of the connector part;
A connector main body formed so as to embed at least a part of the primary molded portion and integrally formed on the proximal end side of the peripheral wall portion;
A resin molded product for an electric motor, which is formed integrally with a base end side of the connector main body portion and a base portion for integrating the second terminal group.   A first connecting portion for connecting the terminals to each other is formed on at least a part of the plurality of terminals constituting the first terminal group, and the first connecting portion is exposed to the outside of the primary molding portion. The resin molded product for an electric motor according to claim 1, wherein the resin molded product is arranged.   A second connecting portion for connecting the terminals to each other is formed on at least a part of the plurality of terminals constituting the second terminal group, and the second connecting portion is exposed to the outside of the secondary molding portion. The resin molded product for an electric motor according to claim 1 or 2, wherein the resin molded product is arranged.   The resin molding for an electric motor according to claim 3, wherein an opening that penetrates in the thickness direction is formed in the base portion, and the second connecting portion is exposed to the outside through the opening. Goods. The connector main body portion is erected so as to be substantially orthogonal to the base portion,
A flat surface is formed around the connector main body portion of the base portion, and the flat surface is configured as a seal surface for ensuring a sealing property with a fixed member to which the resin main body is fixed. The resin molded product for an electric motor according to any one of claims 1 to 4, wherein the resin molded product is an electric motor.   6. The primary molded portion according to claim 5, wherein a flange portion is formed at a portion corresponding to a base end portion of the connector portion, and the flat surface is formed so as to cover the flange portion. The resin molded product for electric motors as described. A resin molded product for an electric motor according to any one of claims 1 to 6,
A motor housing which is a fixed member to which the resin molded product for the electric motor is fixed;
A stator housed in the motor housing and electrically connected to an external device via the resin molded product for the motor;
An electric motor comprising: a rotor rotatably supported in the motor housing. An electric motor according to claim 7,
An electric pump comprising: a pump unit integrated with the motor housing and driven by the electric motor. Manufacturing of a resin molded product for an electric motor in which a first terminal group and a second terminal group constituted by a plurality of terminals are embedded in a resin body, and a connector portion into which a connector extending from an external device can be fitted is integrally formed. A method,
A primary molding step of integrating the first terminal group, and forming a primary molding portion so that one end of the first terminal group becomes a connector terminal protruding into the connector portion;
The peripheral wall portion constituting the peripheral wall of the connector portion, the connector main body portion integrally formed on the base end side of the peripheral wall portion, and the base end side of the connector main body portion so that the primary molding portion is embedded A method for producing a resin molded product for an electric motor, comprising: a secondary molding step of forming a secondary molding portion that is integrally formed and includes a base portion that integrates the second terminal group.   The primary molding step is performed in a state where at least some of the plurality of terminals constituting the first terminal group are connected in advance, and primary separation is performed to separate each terminal after forming the primary molding portion. It has a process, The manufacturing method of the resin molded product for electric motors of Claim 9 characterized by the above-mentioned.   The secondary molding step is performed in a state where at least a part of the plurality of terminals constituting the second terminal group is connected in advance, and after the formation of the secondary molding portion, secondary separation is performed to separate each terminal. It has a process, The manufacturing method of the resin molded product for electric motors of Claim 9 or Claim 10 characterized by the above-mentioned. The secondary molding step forms an opening penetrating in the thickness direction in the base portion,
The said opening part is formed so that the site | part which has connected the said some terminal which comprises the said 2nd terminal group may be exposed, The resin molded product for electric motors of Claim 11 characterized by the above-mentioned. Method. The connector main body portion is erected so as to be substantially orthogonal to the base portion,
The electric motor according to any one of claims 9 to 12, wherein the secondary forming step is performed such that a flat surface is formed around the connector main body portion of the base portion. Manufacturing method of resin molded product. The primary molding step is performed so as to form a flange portion in a portion corresponding to the base end portion of the connector portion in the primary molding portion,
The method for producing a resin molded product for an electric motor according to claim 13, wherein the flat surface is formed so as to cover the flange portion.

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