JP3716777B2 - Manufacturing method of concentrated power distribution member of thin brushless motor for vehicle - Google Patents

Description

[0001]
BACKGROUND OF THE INVENTION
The present invention relates to a method for manufacturing a concentrated power distribution member of a thin brushless motor for a vehicle.
[0002]
[Prior art]
In recent years, there has been a great need for low fuel consumption of vehicles, and as one example, development of a super high fuel consumption hybrid car is underway. Particularly recently, a hybrid car having an auxiliary power mechanism (motor assist mechanism) that uses the engine as a main power and assists the engine with a DC brushless motor at the time of acceleration or the like has been proposed.
[0003]
By the way, since the brushless motor which comprises a motor assist mechanism is arrange | positioned in the limited space in an engine room, specifically, the narrow space between an engine and a transmission, it receives a big restrictions on installation. Therefore, this type of brushless motor is required to be thin.
[0004]
A thin brushless motor for a vehicle used in a motor assist mechanism includes a rotor directly connected to an engine crankshaft and a ring-shaped stator surrounding the rotor. The stator is composed of a large number of magnetic poles formed by winding the core, a stator holder that accommodates the magnetic poles, a concentrated power distribution member (so-called bus ring) for performing concentrated power distribution on the windings, and the like. ing.
[0005]
Conventionally, in producing a concentrated power distribution member of a thin brushless motor for a vehicle, bus bars for U, V, W, and three phases are individually punched and formed in a ring shape using different molds. Therefore, the inventors of the present application further developed this and considered to form a ring-shaped concentrated power distribution member using a bus bar which was punched into a strip shape and then curved in an annular shape.
[0006]
When manufacturing this new concentrated power distribution member, first, the bus bar main body, the terminal portion, and the tab are integrally formed by press molding. Next, after bending the terminal portion, bending the entire bus bar, etc., this is accommodated in the holding groove of the ring-shaped insulating holder. Then, each bus bar and the insulating holder are arranged in the cavity of the insert molding die, and in this state, resin is supplied into the cavity. As a result, each bus bar and insulating holder are entirely covered with the resin insulating layer.
[0007]
[Problems to be solved by the invention]
However, since resin pressure is applied during insert molding, if the insulating holder is not fixed at all, the insulating holder is largely displaced in the vertical direction in the cavity, and the resin insulating layer is partially thinned. In this case, excellent waterproofness and airtightness cannot be imparted to the concentrated power distribution member, and it is expected that a desired withstand voltage cannot be realized.
[0008]
As a measure for preventing the above-mentioned positional deviation, a method is conceivable in which insert pins are formed while projecting support pins on the inner wall surfaces of the upper die and the lower die, and supporting the insulating holder with these support pins. However, in this method, the displacement of the insulating holder is eliminated, but the hole of the support pin remains in the product, and it is impossible to deny the entry of moisture or the like from that portion, and the waterproofness and airtightness are also lowered. Resulting in.
[0009]
The present invention has been made in view of the above problems, and an object of the present invention is to provide a method capable of relatively easily and reliably manufacturing a concentrated power distribution member of a thin brushless motor for a vehicle excellent in waterproofness and dielectric strength. There is.
[0010]
[Means for Solving the Problems]
  According to the first aspect of the present invention, a plurality of bus bars having a terminal portion connected to the battery and a tab connected to the winding of the stator and corresponding to each phase of the motor, and the bus bars are predetermined An insulating holder having a holding groove that holds the gap at an interval, and formed by insert molding, covering each bus bar and the insulating holderInsulating resin layerA ring-shaped concentrated power distribution member capable of intensively distributing current to the windings, wherein an insulating holder holding each bus bar is disposed in a cavity of an insert molding die The upper surface of the insulating holder is projected from the inner wall of the upper mold.And a cross-sectional shape capable of pressing both the upper end edge of the wall portion constituting the holding groove and the upper end edge of each bus bar.It is supported by the upper mold side support body, and the bottom surface side is supported by the lower mold side support body projecting from the inner wall surface of the lower mold.Insulating resin layerThe gist is to insert-mold the insulating holder in a state of being floated in the cavity by retracting the both supports while supplying the molding resin.
[0011]
  According to the first aspect of the present invention, in the cavity, the insulating holder holding each bus bar is supported by the upper mold side support body having the upper surface projecting from the inner wall surface of the upper mold, and the lower surface side is the lower mold. It is supported by a lower mold side support projecting on the inner wall surface. In this state, in the cavityInsulating resin layerResin for molding is supplied. And to some extentInsulating resin layerWhen the molding resin is supplied, both supports are retracted while supplying the resin. Thereby, insert molding is performed with the insulating holder floating in the cavity. At this time, the punch hole generated by the withdrawal of the support isInsulating resin layerFilled with continued supply of molding resin. Therefore, the waterproofness and airtightness of the concentrated power distribution member are improved, and the withstand voltage is increased.In addition, when the insulating holder that holds each bus bar is placed in the cavity of the insert molding die, both the upper edge of the wall portion forming the holding groove and the upper edge of each bus bar are pressed by the upper mold side support. Is done. In this way, the insulating holder is positioned and fixed more reliably at the initial stage of insert molding. Therefore, it is possible to reliably prevent the insulating holder from inadvertently tilting before supplying the resin into the cavity.
[0012]
  According to a second aspect of the present invention, in the manufacturing method of the concentrated power distribution member of the thin brushless motor for a vehicle according to the first aspect,The insulating holder is provided with a positioning portion for positioning and fixing the insulating holder in contact with the inner wall surface of the lower mold during insert molding.It is a summary.
[0013]
  According to invention of Claim 2,The insulating holder is positioned and fixed by abutting the positioning portion against the inner wall surface of the lower mold. Therefore, even if both supports are retracted and the insulating holder is floating in the cavity, the positioning is continued. Therefore, it is possible to more reliably prevent the insulating holder from being displaced during insert molding.
[0014]
  In the invention according to claim 3, the claim1In the manufacturing method of the concentrated power distribution member of the thin brushless motor for a vehicle described inThe rib is surrounded by a rib protruding from the bottom surface of the insulating holder, and a non-penetrating recess having a notch is formed in the rib. The insulating holder and each bus bar are placed in the cavity of the insert molding die. When arranging, the tip of the lower mold side support projectingly provided on the inner wall surface of the lower mold is engaged with the recess, and in this state, the resin for forming the insulating resin layer is supplied into the cavity.This is the gist.
[0015]
  According to invention of Claim 3,In the state in which the lower mold side support is protruded, the distal end of the lower mold side support is engaged with the non-penetrating recess provided in the insulating holder, so that the displacement of the insulating holder can be prevented. Therefore, since the insulating holder can be held at a predetermined position in the cavity, the synthetic resin can be coated with a uniform thickness around the insulating holder.
[0016]
DETAILED DESCRIPTION OF THE INVENTION
Hereinafter, an embodiment of the present invention will be described with reference to the drawings.
As shown in FIG. 1, a three-phase thin DC brushless motor 11 used in a hybrid vehicle is disposed between an engine 12 and a transmission 13. The thin brushless motor 11 includes a rotor 14 that is directly connected to a crankshaft of the engine 12 and a ring-shaped stator 15 that surrounds the rotor 14. The stator 15 includes a large number of magnetic poles formed by applying windings 16 to the core, a stator holder that accommodates the magnetic poles, an annular concentrated power distribution member 17 for distributing power to the windings 16, and the like. FIG. 2 is a schematic diagram of the stator 15. As shown in the figure, each phase winding 16 has one end connected to bus bars 22a, 22b, and 22c provided on the concentrated power distribution member 17, and the other end connected to a ring-shaped conductive member (not shown). Yes.
[0017]
As shown in FIGS. 3 to 6, the central power distribution member 17 has a continuous annular insulating holder 21 made of a natural color synthetic resin embedded therein. As a forming material of the insulating holder 21, for example, PBT (polybutyrene terephthalate), PPS (polyphenylene sulfide), or the like can be used.
[0018]
In the present embodiment, PPS in which about 40% of glass fiber is added to the forming material of the insulating holder 21 is employed. The reason for adopting this material for the insulating holder 21 is that it has excellent electrical characteristics (insulation breakdown voltage). In particular, in the thin brushless motor 11 according to the present embodiment, the voltage applied to the bus bars 22a, 22b, and 22c of each phase is high, so that it is important to ensure the dielectric strength of the bus bars 22a, 22b, and 22c. I can say that. In this case, the withstand voltage is required to be at least 2000V. In addition, PPS has not only extremely high heat resistance but also excellent mechanical strength compared to general-purpose resins such as PP (polypropylene).
[0019]
As shown in FIGS. 8, 9, and 10, three holding grooves 23 a, 23 b, and 23 c that extend along the circumferential direction are recessed in one side surface of the insulating holder 21. The holding grooves 23a, 23b, and 23c are juxtaposed in the radial direction of the insulating holder 21 with parallel intervals. Bus bars 22a, 22b, and 22c corresponding to the respective phases are individually inserted into the holding grooves 23a, 23b, and 23c. The respective bus bars 22a, 22b, and 22c are stacked in the radial direction of the concentrated power distribution member with a predetermined distance therebetween. Therefore, the holding grooves 23a, 23b, and 23c have a role of relatively holding the inserted bus bars 22a, 22b, and 22c at accurate positions. The insulating holder 21 and the bus bars 22a, 22b, and 22c are entirely covered with an insulating resin layer 25. By this covering, the bus bars 22a, 22b, and 22c are insulated.
[0020]
The insulating resin layer 25 is made of PPS to which glass fibers are added, the same as the insulating holder 21. The reason for adopting this material for the insulating resin layer 25 is the same reason as that for the insulating holder 21 and is excellent in electrical characteristics (insulation withstand voltage), heat resistance, and mechanical strength. However, natural resin is also used as the material of the insulating resin layer 25.
[0021]
In the present embodiment, the bus bar 22a located on the inner side corresponds to the W phase, the bus bar 22b located on the middle corresponds to the U phase, and the bus bar 22c located on the outer side corresponds to the V phase. Hereinafter, for the sake of easy understanding, the W-phase bus bar 22a is expressed as "inner bus bar 22a", the U-phase bus bar 22b is expressed as "intermediate bus bar 22b", and the V-phase bus bar 22c is expressed as "outer bus bar 22c". To do.
[0022]
Each bus bar 22a, 22b, 22c will be described. The bus bars 22a, 22b, and 22c are incomplete circles in which a conductive metal plate material made of a copper plate, a copper alloy, or the like is punched into a band shape by a press device in advance in a thickness direction so that there is no part of an arc. It is shaped like a ring (substantially C-shaped). In addition, each of the bus bars 22a, 22b, and 22c is set to be larger as the diameter is on the outer side. And since each shaped bus-bar 22a, 22b, 22c is inserted in each holding groove 23a, 23b, 23c, the assembly | attachment of bus-bar 22a, 22b, 22c with respect to the insulation holder 21 becomes easy. .
[0023]
As shown in FIGS. 8 to 11, a plurality of tabs 41 a, 41 b, 41 c to which one end of the winding 16 is connected project from one side edge of each bus bar 22 a, 22 b, 22 c. Each of the tabs 41a, 41b, 41c is punched simultaneously with the punching of the conductive metal plate material, which is a material for forming the bus bars 22a, 22b, 22c. Accordingly, the bus bars 22a to 22c and the tabs 41a to 41c are integrally formed in a connected state through a single pressing step. This is because the manufacturing process can be simplified compared to the case where the bus bars 22a, 22b, 22c and the tabs 41a, 41b, 41c are retrofitted by welding or the like.
[0024]
Each of the tabs 41a, 41b, 41c is provided in six for each bus bar 22a, 22b, 22c. The tabs 41a, 41b, and 41c of each phase are arranged at equal intervals along the circumferential direction of the bus bars 22a, 22b, and 22c, that is, at a central angle of 60 °.
Then, the separation portions 42 of the respective bus bars 22a to 22c are arranged so as to be shifted from each other by 20 ° in the circumferential direction, so that a total of 18 tabs 41a to 41c are circumferentially centered on the central portion of the concentrated power distribution member 17 Are arranged at equal intervals, that is, with a central angle of 20 °. Incidentally, as shown in FIG. 11, in the present embodiment, the intermediate bus bar 22 b is arranged so as to be shifted by + 20 ° in the clockwise circumferential direction when the separation portion 42 of the outer bus bar 22 c is used as a reference. On the other hand, the inner bus bar 22a is arranged to be shifted by −20 ° in the counterclockwise direction.
[0025]
The tabs 41 a, 41 b, 41 c of the bus bars 22 a, 22 b, 22 c are each bent in a substantially L-shaped cross section so that the tip faces the center of the concentrated power distribution member 17. And the front-end | tip part of each tab 41a, 41b, 41c protrudes outward from the internal peripheral surface of the concentrated power distribution member 17. FIG. The winding 16 is connected to the protruding portion. The tabs 41 a, 41 b, 41 c have different lengths, and their tips are located on the same circumference centered on the central portion of the concentrated power distribution member 17. Therefore, the tabs 41a, 41b, 41c of the bus bars 22a, 22b, 22c located on the outer side are longer in the radial direction of the concentrated power distribution member 17.
[0026]
As shown in FIGS. 15A and 15B, the portions of the tab 41b of the intermediate bus bar 22b covered with the insulating resin layer 25 are provided with wall portions 43a, 43b, A curved portion 44 that swells in the height direction of 43c and 43d is formed. The curved portion 44 bypasses the upper edge portion of the inner bus bar 22a (other bus bars) in the insulating resin layer 25. The reason why the curved portion 44 is provided is to ensure a creepage distance.
[0027]
As shown in FIGS. 16A and 16B, a curved portion 45 that swells in the height direction of the wall portions 43a to 43d is formed at a portion of the tab 41c of the outer bus bar 22c that is covered with the insulating resin layer 25. Has been. The curved portion 45 bypasses not only the inner bus bar 22a but also the upper edge portion of the intermediate bus bar 22b (all other bus bars) in the insulating resin layer 25. The reason why the curved portion 45 is provided is to secure a creeping distance as in the curved portion 44 described above. The curved portion 45 here is longer than the curved portion 44 of the tab 41b in the intermediate bus bar 22b because it bypasses the upper ends of the two bus bars 22a and 22b.
[0028]
As shown in FIGS. 14A and 14B, the base end portion of the tab 41a on the inner bus bar 22a does not have the curved portions 44 and 45 as described above, and is simply bent at 90 °. It is. This is because there is no other bus bar on the side where the tab 41a is bent, and therefore it is not necessary to ensure the creepage distance.
[0029]
As shown in FIGS. 14A and 14B, at the end of the wall portion 43b that separates the tab forming portion of the inner bus bar 22a and the tab non-forming portion of the intermediate bus bar 22b adjacent to the inner bus bar 22a. The inner small protrusion 47 is integrally formed. The reason why the inner small protrusions 47 are provided is to secure a creepage distance between the inner bus bar 22a and the intermediate bus bar 22b adjacent thereto. The inner small protrusions 47 are made of synthetic resin and are provided in total, and they are arranged at equal intervals along the circumferential direction of the insulating holder 21. Each inner small protrusion 47 corresponds to each tab 41a provided on the inner bus bar 22a. Further, the height of the wall 43b having the inner small protrusions 47 is higher than the height of the wall 43b that separates the tab non-formed portions of the inner bus bar 22a and the intermediate bus bar 22b. In the description of this paragraph, “a specific bus bar” refers to the inner bus bar 22a, and “another bus bar” refers to the intermediate bus bar 22b.
[0030]
As shown in FIGS. 15A and 15B, at the end of the wall portion 43c that separates the tab forming portion of the intermediate bus bar 22b from the tab non-forming portion of the outer bus bar 22c adjacent to the intermediate bus bar 22b. The outer small protrusion 48 is integrally formed. The reason why the outer small protrusions 48 are provided is to ensure a creepage distance between the intermediate bus bar 22b and the outer bus bar 22c adjacent thereto. The outer small protrusions 48 are made of synthetic resin and are provided in total, and are arranged at equal intervals along the circumferential direction of the insulating holder 21. Each outer small protrusion 48 corresponds to each tab 41b provided on the intermediate bus bar 22b. Further, the height of the wall 43c having the outer small protrusion 48 is higher than the height of the wall 43c that separates the non-formed portions of the intermediate bus bar 22b and the outer bus bar 22c. In the description of this paragraph, “a specific bus bar” refers to the intermediate bus bar 22b, and “another bus bar” refers to the outer bus bar 22c.
[0031]
As shown in FIGS. 3 to 7, one terminal portion 50 w, 50 u, 50 v is integrally formed on one side edge of each bus bar 22 a, 22 b, 22 c, respectively, and they are the outer periphery of the insulating resin layer 25. It protrudes from a part of the surface. Each terminal part 50u, 50v, 50w is connected to the battery (not shown) of the thin brushless motor 11 via the power cable 51 shown in FIG. Each of the terminal portions 50u, 50v, 50w is punched at the same time when a conductive metal plate material, which is a material for forming the bus bars 22a, 22b, 22c, is punched with a press device. Therefore, the bus bars 22a to 22c and the terminal portions 50u, 50v, and 50w are integrally formed in a connected state through a single pressing process. This can simplify the manufacturing process as compared with the case where the bus bars 22a, 22b, 22c and the terminal portions 50u, 50v, 50w are retrofitted by welding or the like.
[0032]
As shown in FIGS. 6 and 7, a bolt insertion hole 52 through which a mounting bolt (not shown) of the power cable 51 is inserted is provided at the tip of the terminal portions 50 u, 50 v, 50 w. On the outer peripheral surface of the insulating resin layer 25, there is integrally formed a resin accommodating portion 53 that surrounds the periphery from the base end portion of each terminal portion 50u, 50v, 50w to the center portion, and has insulation inside. A sealing material 54 made of a thermosetting resin is filled. In the terminal portions 50 u, 50 v, 50 w, portions that are proximal to the bolt insertion holes 52 and exposed from the insulating resin layer 25 are embedded with a sealing material 54. By sealing a part of each terminal part 50u, 50v, 50w with this sealing material 54, waterproofness and airtightness are improved. In the present embodiment, a silicone-based thermosetting resin is used as the sealing material 54. The thermosetting resin can be arbitrarily changed in addition to the silicone type.
[0033]
FIG. 28 is a developed view of the bus bars 22a, 22b, and 22c. As shown in the figure, the terminal portions 50u, 50v, 50w are arranged at substantially the center portion in the longitudinal direction of each bus bar 22a, 22b, 22c. The number of tabs 41a, 41b, 41c on both sides of each terminal portion 50u, 50v, 50w is the same. Specifically, three tabs 41a, 41b, and 41c are provided on one side of each terminal portion 50u, 50v, and 50w, and three tabs 41a, 41b, and 41c are provided on the other side. The reason why the same number of tabs 41a, 41b, and 41c are provided on both sides of the terminal portions 50u, 50v, and 50w is to allow the same current to flow through the tabs 41a, 41b, and 41c.
[0034]
As shown in FIGS. 6 and 8, each of the terminal portions 50 u to 50 w has an embedded portion 55 covered with the sealing material 54 at the base end portion and the bolt insertion hole 52, and the sealing material 54 It is divided into an exposed portion 56 that is not covered. The embedded portion 55 is press-molded, and the central portion thereof is bent obliquely. The reason why the inclined portion 55a is formed in this way is that it can use less material than bending the central portion of the embedded portion 55 at a right angle, and contributes to the weight reduction of the bus bars 22a, 22b, and 22c. It is.
[0035]
Slits 57a and 57b are formed in both end portions of the buried portion 55 in each terminal portion 50u, 50v, and 50w. Both slits 57a, 57b extend along the longitudinal direction of the terminal portions 50u, 50v, 50w. Then, a portion of the embedded portion 55 is thinned by the two slits 57a and 57b, and the width of the embedded portion 55 in that portion is shorter than the width of the portion that is not thinned. The reason for this configuration is to reduce the difference in heat shrinkage between the insulating resin layer 25 and the bus bars 22a to 22c when the insulating resin layer 25 covering the periphery of the insulating holder 21 is cooled by insert molding. Because. The number and width of the slits 57a, 57b can be arbitrarily changed as long as the strength of the terminal portions 50u, 50v, 50w is not impaired. For example, it is possible to provide two slits 57 a and 57 b at both ends of the embedded portion 55.
[0036]
As shown by cross hatching in FIG. 8, tin plating is applied to a part of the exposed portion 56 and the embedded portion 55 in the terminal portions 50 u, 50 v, 50 w. Specifically, tin plating is applied from the tip of the exposed portion 56 to the vicinity of the central portion of the oblique portion 55a in the embedded portion 55. The reason for this tin plating is to prevent oxidative corrosion of the surfaces of the bus bars 22a, 22b, and 22c.
[0037]
The terminal portions 50u, 50v, and 50w are obtained by bending with the first press device 60 shown in FIGS. 18 and 19 and further bending with the second press device 61 shown in FIG.
[0038]
First, the 1st press apparatus 60 is demonstrated. As shown in FIGS. 18 and 19, the first press device 60 is for bending the terminal portions 50u, 50v, and 50w. The first press device 60 includes a lower mold 62 that is a fixed mold and an upper mold 63 that is a movable mold. Then, when the upper mold 63 approaches the lower mold 62, both molds 62 and 63 are closed. On the other hand, when the upper mold 63 is separated from the lower mold 62, both molds 62 and 63 are opened.
[0039]
On the upper surface of the lower mold 62, a lower mold side molding recess 62a having a V shape and a lower mold side molding protrusion 62b having a V shape are formed adjacent to each other. A pilot pin 64 projects from the upper end of the lower mold side molding projection 62b. The pilot pin 64 positions the terminal portions 50u, 50v, and 50w by penetrating through a pilot hole 65 that is formed through the oblique portions 55a of the terminal portions 50u, 50v, and 50w.
[0040]
On the other hand, on the lower surface of the upper mold 63, an upper mold side molding protrusion 63a having a V shape and an upper mold side molding recess 63b having a V shape are formed adjacent to each other. The upper mold side molding projection 63a and the lower mold side molding recess 62a face each other, and the one upper mold side molding recess 63b and the lower mold side molding projection 62b face each other. Therefore, when the upper mold 63 approaches the lower mold 62 and closes the mold, both molds 62 and 63 are engaged with each other due to the unevenness. A retracting recess 66 is formed in the inner back surface of the upper mold side forming recess 63b. And when both mold | types 62 and 63 are closed, the pilot pin 64 and the upper mold | type 63 do not interfere with each other by inserting the pilot pin 64 in this retracting recessed part 66. FIG.
[0041]
Then, the 2nd press apparatus 61 is demonstrated.
As shown in FIG. 20, the 2nd press apparatus 61 bends and forms the boundary part of terminal part 50u, 50v, 50w and bus-bar 22a, 22b, 22c. The second press device 61 includes a lower mold 67 that is a fixed mold and an upper mold 68 that is a movable mold. Then, when the upper mold 68 approaches the lower mold 67, both molds 67 and 68 are closed. On the other hand, when the upper mold 68 is separated from the lower mold 67, both molds 67 and 68 are opened.
[0042]
On the upper surface of the lower mold 67, there is formed a lower mold side molding protrusion 67a with which the embedded portion 55 in the terminal portions 50u, 50v, 50w is engaged. An insertion pin 69 for positioning the terminal portions 50u, 50v, and 50w is projected from a location located in the vicinity of the lower mold side projection 67a in the lower mold 67. When the terminal portions 50 u, 50 v, 50 w are set in the lower mold 67, the insertion pin 69 is inserted through the bolt insertion hole 52. In a state where the insertion pin 69 has penetrated, the terminal portions 50u, 50v, 50w are prevented from being displaced.
[0043]
On the lower surface of the upper mold 68, an upper mold side molding recess 68a facing the lower mold side molding protrusion 67a is formed. Then, when the upper mold 68 approaches the lower mold 67 and closes the mold, the molds 67 and 68 are engaged with each other due to the concavo-convex relationship between the both parts 67a and 68a. The upper mold 68 excluding the upper mold side molding recess 68a is set to a thickness that does not interfere with the insertion pin 69 in the lower mold 67 when both the molds 67, 68 are closed.
[0044]
As shown in FIGS. 18B and 21, the first press device 60 and the second press device 61 extend in the width direction at portions where the terminal portions 50 u, 50 v, and 50 w are bent. A plurality of notches 59 are recessed. The notches 59 are respectively provided on both surfaces of a strip-shaped forming material 92 that is obtained by punching a conductive metal plate material before forming the terminal portions 50u, 50v, 50w. In the present embodiment, one is provided on one surface of the strip-shaped molding material 92 corresponding to the terminal portions 50u, 50v, and 50w, and three are provided on the other surface. And the site | part which provided the notch 59 in the strip | belt-shaped molding material 92 is bent inside.
[0045]
Next, the process of bending the terminal portions 50u, 50v, 50w using the first press device 60 and the second press device 61 configured as described above will be described.
As shown in FIGS. 18A and 18B, a plate shape in which a conductive metal plate material is punched into a predetermined shape on the upper surface of the lower die 62 in a state where both the dies 62 and 63 of the first press device 60 are opened. The belt-shaped molding material 92 is placed. Then, the pilot pin 64 of the lower mold 62 is passed through the pilot hole 65 formed in the band-shaped molding material 92 so that the band-shaped molding material 92 is not displaced. Further, the belt-shaped molding material 92 is prevented from being displaced by engaging the end of the belt-shaped molding material 92 on the side having the bolt insertion holes 52 with the lower mold 62.
[0046]
As shown in FIGS. 19A and 19B, when both molds 62 and 63 are closed, the belt-shaped molding material 92 is formed between the lower mold-side molding recess 62a and the upper mold-side molding projection 63a. It is sandwiched between the side molding projection 62b and the upper mold side molding recess 63b. Thereby, the band-shaped molding material 92 corresponding to the terminal portions 50u, 50v, 50w is bent, and the terminal portions 50u, 50v, 50w are molded. Thereafter, both molds 62 and 63 are opened, and a strip-shaped molding material 92 in which only the terminal portions 50u, 50v, and 50w are molded is taken out between them.
[0047]
  Next, as shown in FIGS. 20 (a) and 20 (b), in a state in which both dies 67 and 68 of the second press device 61 are opened, the lower die67Lower mold side moldingProjection 67aThe terminal portions 50u, 50v, 50w molded by the first press device 60 are engaged with each other. At the same time, the insertion pins 69 are passed through the bolt insertion holes 52 formed in the terminal portions 50u, 50v, 50w so that the band-shaped molding material 92 is not displaced.
[0048]
When both molds 67 and 68 are closed, the end portion of the strip-shaped molding material 92, that is, the portion corresponding to the bus bars 22a, 22b, and 22c is the gap between the lower mold-side molding protrusion 67a and the upper mold-side molding recess 68a. Sandwiched between. Thereby, the boundary part of bus-bar 22a, 22b, 22c and terminal part 50u, 50v, 50w is bent at a right angle. Thereafter, both molds 62 and 63 are opened, and a strip-shaped molding material 92 in which only the terminal portions 50u, 50v, and 50w are molded is taken out between them.
[0049]
As shown in FIGS. 24 to 27, the insulating resin layer 25 covering the insulating holder 21 is molded by an insert molding die 70. The insert molding die 70 includes a lower die 71 that is a fixed die and an upper die 72 that is a movable die. The upper mold 72 can be moved closer to and away from the lower mold 71, and the mold is closed when the upper mold 72 approaches, and the mold is opened when the upper mold 72 is separated.
[0050]
The lower mold 71 and the upper mold 72 are formed with molding recesses 71a and 72a facing each other. When both the molds 71 and 72 are closed, an annular cavity 73 is formed by the two molding recesses 71a and 72a facing each other. The cavity 73 is filled with a molten resin material 90 for forming the insulating resin layer 25 through a gate (not shown). A plurality of gates are provided on the inner peripheral surface of the lower mold 71 (the left surface in FIGS. 24 to 27). Moreover, the gates are provided at equal intervals along the inner peripheral surface of the lower mold 71. Thereby, the pressure of the molten resin material 90 applied to the insulating holder 21 in the cavity 73 is equalized.
[0051]
The upper mold 72 is provided with an upper mold side support 80 that presses the upper surface of the insulating holder 21 accommodated in the cavity 73. The upper mold side support body 80 can be projected and retracted from the inner top surface of the upper molding recess 72a. Although not shown, a plurality of upper mold side supports 80 (18 in this embodiment) are provided. The upper mold side support bodies 80 are arranged at equal intervals along the circumferential direction of the insulating holder 21 except for the places where the terminal portions 50u, 50v, 50w are arranged. When the upper mold-side support 80 protrudes, the plurality of locking grooves 81 recessed in the front end surface are formed by the upper end portion of the wall portion 43b separating the inner bus bar 22a and the intermediate bus bar 22b, and the intermediate bus bar. It engages with the upper end of the wall 43c that separates the outer bus bar 22c and the outer bus bar 22c. In this engaged state, the tip surface of the upper mold side support 80 is brought into contact with the upper edge of each bus bar 22a, 22b, 22c. Thereby, the upper side of the insulating holder 21 (the upper side of the holder 21 shown in FIG. 24) is pressed by the upper mold side support body 80.
[0052]
The lower mold 71 is provided with a holder support pin 74 as a holder support for supporting the insulating holder 21 accommodated in the cavity 73. The holder support pin 74 can be projected and retracted into the cavity 73 from the vicinity of the bottom surface of the lower molding recess 71a. Although not shown, a plurality of holder support pins 74 (36 in this embodiment) are provided, and they are arranged at equal intervals along the circumferential direction of the insulating holder 21.
[0053]
As shown in FIGS. 22, 23 (a) and 23 (b), in the state where the holder support pin 74 protrudes, its tip is engaged with a non-penetrating recess 75 formed on the lower surface of the insulating holder 21. . By this engagement, when the insulating holder 21 is accommodated in the cavity 73, the insulating holder 21 is not displaced.
[0054]
The non-penetrating recess 75 is formed in a taper shape and is reduced in diameter toward the inner top. Therefore, the holder support pin 74 is finally engaged with the non-penetrating recess 75 while the holder support pin 74 is guided to the inner peripheral surface of the non-penetrating recess 75. Therefore, when the insulating holder 21 is set in the lower molding recess 71 a of the lower mold 71, the holder support pin 74 is not disposed away from the non-penetrating recess 75.
[0055]
Two arc-shaped ribs 76 a and 76 b project from the bottom surface of the insulating holder 21 at positions around the holder support pins 74. Due to the presence of the ribs 76a and 76b, the holder support pin 74 engaged with the non-penetrating recess 75 does not come off.
[0056]
A plurality (two in this embodiment) of notches 77a and 77b are formed between the ribs 76a and 76b. Due to the presence of the notches 77a and 77b, when the holder support pin 74 is removed from the non-penetrating recess 75 during the insert molding of the insulating resin layer 25, the non-penetrating recess 75 side is provided via the notches 77a and 77b. Therefore, the resin for forming the insulating resin layer 25 can easily go around. In the concentrated power distribution member 17 finally manufactured, the non-penetrating recess 75 is filled with the insulating resin layer 25. Note that the number of the ribs 76a and 76b and the notches 77a and 77b can be arbitrarily changed. For example, by making the number of ribs 76a and 76b one and making the overall shape C-shaped, the notches 77a and 77b can be made one.
[0057]
As shown in FIGS. 22, 23, and 14 to 16, the bottom of the insulating holder 21 is provided with a communication hole 78 that communicates with the inside of each holding groove 23 a, 23 b, 23 c. The communication hole 78 is provided so that the resin for forming the insulating resin layer 25 can easily enter the holding grooves 23a, 23b, and 23c during the insert molding. A plurality of communication holes 78 are provided along the circumferential direction of the insulating holder 21. Strictly speaking, each communication hole 78 is arranged along each holding groove 23a, 23b, 23c. Moreover, as shown in FIG. 10, the communication holes 78 are arranged with their positions shifted in the circumferential direction of the insulating holder 21. This means that only one communication hole 78 is arranged on the same line in the radial direction of the insulating holder 21.
[0058]
As shown in FIGS. 22 and 24, when the insulating holder 21 is set on the lower mold 71, the positioning protrusion 82 as a positioning portion where the front end surface abuts against the inner surface of the lower molding concave portion 71 a is the insulating holder 21. It is formed on the inner peripheral surface. A plurality of positioning protrusions 82 are provided, and they are arranged at equal intervals along the circumferential direction of the insulating holder 21. Since all the positioning protrusions 82 abut against the inner surface of the lower molding recess 71a, the insulating holder 21 is not displaced in the radial direction.
[0059]
As shown in FIGS. 9, 12, and 13, each holding groove 23 a to 23 c in the insulating holder 21 includes a bus bar housing part 83 in which the bus bars 22 a to 22 c are accommodated and a bus bar non-accommodating part 84 that is not accommodated. It is divided into and. A plurality of first reinforcing ribs 85 are provided at intervals in the circumferential direction of the insulating holder 21 in the holding grooves 23 a, 23 b, and 23 c in the bus bar non-accommodating portion 84. Each first reinforcing rib 85 is formed integrally with the bottom and inner side surfaces of the wall portions 43a to 43d separating the holding grooves 23a, 23b, and 23c.
[0060]
The communication holes 78 that facilitate the flow of the molten resin material 90 into the holding grooves 23a, 23b, and 23c are formed on the bottom surfaces of the holding grooves 23a, 23b, and 23c located at the respective portions 83 and 84. Thereby, the molten resin material 90 is easily filled in the entire holding grooves 23a, 23b, and 23c.
[0061]
The bus bar housing part 83 in the insulating holder 21 is provided with three holding grooves 23a, 23b, and 23c, whereas the bus bar non-housing part 84 is provided with only two holding grooves 23a and 23b. That is, in the bus bar non-accommodating portion 84, there is no outermost holding groove 23c. Accordingly, the bus bar non-accommodating portion 84 in the insulating holder 21 is narrower than the bus bar accommodating portion 83.
[0062]
  Furthermore, the bus bar in the insulating holder 21NonContainment site 84A second reinforcing rib 86 projects from the outer peripheral surface of the insulating holder 21 along the circumferential direction of the insulating holder 21. The second reinforcing rib 86 is formed in an arc shape, and its radius of curvature is set to be the same as the radius of the insulating holder 21.
[0063]
Next, a method of insert molding the concentrated power distribution member 17 using the insert molding die 70 configured as described above will be described.
With the mold opened, the insulating holder 21 is placed in the lower molding recess 71a of the lower mold 71. Then, the non-penetrating recess 75 of the insulating holder 21 is engaged with the tip of the holder support pin 74 protruding into the lower molding recess 71a. As a result, the insulating holder 21 is supported at a constant interval from the bottom surface of the lower molding recess 71a. At this time, each of the plurality of positioning protrusions 82 provided on the insulating holder 21 is in contact with the inner peripheral surface of the lower molding recess 71a. Therefore, the displacement of the insulating holder 21 in the radial direction is restricted.
[0064]
As shown in FIG. 24, when the upper mold 72 approaches the lower mold 71 and the mold is closed, a cavity 73 is formed. At the same time, the front end surface of the upper mold side support 80 protruding into the upper molding recess 72a comes into contact with the upper ends of the bus bars 22a, 22b, and 22c. Further, the locking groove 81 on the tip surface of the upper mold side support 80 is engaged with the wall portions 43b and 43c that partition the holding grooves 23a, 23b, and 23c. Accordingly, the insulating holder 21 and the bus bars 22a, 22b, and 22c are pressed by the upper mold side support 80. As described above, the vertical movement of the insulating holder 21 is restricted by the plurality of holder support pins 74 and the plurality of upper mold side supports 80.
[0065]
As shown in FIG. 25, the cavity 73 is filled with a molten resin material 90 for forming an insulating resin layer through a gate (not shown) formed in the lower mold 71. At this time, the molten resin material 90 filled so as to cover the insulating holder 21 also wraps around the inside through the openings of the holding grooves 23a, 23b, and 23c. In addition, the holding holes 23 a, 23 b, and 23 c also wrap around from the communication holes 78 that are formed through the insulating holder 21. Even when the pressure of the molten resin material 90 is applied to the holding grooves 23a, 23b, 23c of the bus bar non-accommodating portion 84 (see FIG. 12) in the insulating holder 21, the wall portion 43a is formed by the first and second reinforcing ribs 85, 86. ˜43c is not deformed.
[0066]
When the molten resin material 90 reaches almost the entire cavity 73, as shown in FIG. 26, the holder support pin 74 is retracted to the lower mold 71 and the upper mold side support 80 is retracted to the upper mold 72. At this time, the insulating holder 21 is completely lifted without being supported in the cavity 73. However, since the molten resin material 90 continues to be filled in the cavity 73, the insulating holder 21 tilts. There is no. In addition, the hole formed by the retraction of the holder support pin 74 and the upper mold side support 80 is filled with the molten resin material 90. Further, the molten resin material 90 wraps around in or near the non-penetrating recess 75 with which the holder support pin 74 is engaged, and the molten resin material 90 wraps around or near the upper ends of the wall portions 43b and 43c. Thereby, the insulating holder 21 is covered with the molten resin material 90.
[0067]
As shown in FIG. 27, the insulating resin layer 25 is formed by elapse of a predetermined time and the molten resin material 90 is cooled and solidified. Thereafter, the upper mold 72 is separated from the lower mold 71 and the mold is opened, and the concentrated power distribution member 17 in which the insulating holder 21 and the insulating resin layer 25 are integrated is taken out.
[0068]
Next, a method for manufacturing the concentrated power distribution member 17 will be described.
(Punching process of conductive metal sheet)
As shown in FIG. 29, a conductive metal plate 91 is punched out by a pressing device (not shown), and a strip-shaped forming material 92 that is used to bend the bus bars 22a to 22c is manufactured. Since the strip-shaped forming material 92 of each bus bar 22a, 22b, 22c is linear, they can be punched in parallel. This contributes to significantly improving the yield as compared with the case where the strip-shaped molding material 92 is punched in an annular shape.
[0069]
(First bending process for bus bars)
As shown in FIG. 29, the portions corresponding to the terminal portions 50u, 50v, 50w in the band-shaped forming material 92 are bent and formed by the first press device 60 and the second press device 61 already described above.
[0070]
(Second bending for busbar)
As shown in FIG. 29, in the band-shaped molding material 92 after molding the terminal portions 50u, 50v, 50w, the portions corresponding to the bus bars 22a, 22b, 22c are curved in the thickness direction and molded into a substantially annular shape. To do. This molding is performed by a bending apparatus (not shown). Thus, before assembling the bus bars 22a, 22b, and 22c to the insulating holder 21, the bus bars 22a, 22b, and 22c are shaped in a substantially annular shape.
[0071]
(Bus bar insertion process)
As shown in FIG. 30, each bus-bar 22a, 22b, 22c is inserted in the insulation holder 21 already manufactured. Here, it inserts in order from the thing located in the outer side of the insulation holder 21. That is, the outer bus bar 22c, the intermediate bus bar 22b, and the inner bus bar 22a are inserted in this order. The reason why the bus bar is inserted in this order is that if the bus bar is inserted first from the inner bus bar, the bus bar to be inserted later is prevented from being inserted by the terminal portion of the bus bar inserted first.
[0072]
(Third bending for busbar)
As shown in FIG. 31, in a state where the bus bars 22 a to 22 c are assembled to the insulating holder 21, the tabs 41 a, 41 b, 41 c are bent so that the respective tips are directed to the center of the insulating holder 21. At this time, with respect to the intermediate bus bar 22b and the outer bus bar 22c, the curved portions 44 and 45 are formed at the base end portion.
[0073]
(Insert molding)
As shown in FIG. 32, the insulating resin layer 25 is formed on the outer periphery of the insulating holder 21 to which the bus bars 22a, 22b, and 22c are assembled. This molding is performed by the manufacturing method using the insert molding die 70 already described. Thereafter, the concentrated power distribution member 17 is taken out from the insert molding die 70, and finally, the sealing material 54 is filled in the resin housing portion 53 formed in the insulating resin layer 25.
[0074]
Therefore, according to the present embodiment, the following effects can be obtained.
(1) In manufacturing the concentrated power distribution member 17, the holder support pin 74 and the upper mold side support 80 are retracted while the molten resin material 90 is filled in the cavity 73 of the insert molding die 70. By such a method, the hole formed by the retraction of the holder support pin 74 and the upper mold side support 80 is filled with the molten resin material 90. Therefore, the insulating holder 21 is completely covered with the insulating resin layer 25, so that the waterproofness and airtightness of the concentrated power distribution member 17 can be improved, and the withstand voltage can be increased.
[0075]
(2) Since the material of the insulating resin layer 25 uses PPS to which glass fiber is added, for example, the melting temperature of the resin is higher than that of PBT or the like, and tin melts in the insulating resin layer 25 during insert molding. Easy to use. However, since the portions of the bus bars 22a, 22b, and 22c that are covered with the insulating holder 21 are not plated with tin, such a problem does not occur at all. Therefore, it is possible to reliably prevent the breakdown voltage from being lowered due to the dielectric breakdown caused by the tin plating mixed in the insulating resin layer 25.
[0076]
(3) The front end surface of the upper mold side support 80 has irregularities by providing two locking grooves 81. Thereby, both the upper end edge of wall part 43b, 43c which comprises the holding grooves 23a-23c, and the upper end edge of each bus-bar 22a-22c are pressed by the upper mold | type support body 80. FIG. Therefore, when the molten resin material 90 for molding the insulating resin layer 25 is filled in the cavity 73, the insulating holder 21 can be prevented from being displaced from the fixed position. That is, the insulating holder 21 can be held at a predetermined position by the upper mold side support 80. Therefore, the insulating resin layer 25 can be covered with a uniform thickness around the insulating holder 21.
[0077]
(4) The lower die 71 is provided with a holder support pin 74 that can be projected and retracted in the cavity 73. In the state where the holder support pin 74 is projected, the tip end portion thereof is engaged with the non-penetrating recess 75 provided in the insulating holder 21, so that the displacement of the insulating holder 21 can be prevented. Therefore, since the insulating holder 21 can be held at a predetermined position in the cavity 73, the synthetic resin can be coated with a uniform thickness around the insulating holder 21.
[0078]
(5) At the time of insert molding, since the insulating holder 21 is sandwiched and supported by the upper mold side support 80 and the holder support pins 74, the insulating holder 21 can be supported in a state where it is floated in the cavity 73. Therefore, the insulating holder 21 is not displaced in the vertical direction of the insert molding die 70, so that it is possible to reliably prevent the insulating holder 21 from being covered with the insulating resin layer 25 in a tilted state.
[0079]
(6) On the inner peripheral surface of the insulating holder 21, a positioning protrusion 82 is provided that protrudes along the radial direction. The positioning protrusion 82 is formed by contacting the positioning protrusion 82 with the inner surface of the lower molding recess 71a when the insulating holder 21 is set in the lower molding recess 71a of the lower mold 71. 21 does not move in the radial direction. Therefore, the cavity 73 can be filled with the resin for forming the insulating resin layer 25 in a state where the insulating holder 21 is stabilized.
[0080]
(7) The insulation between the bus bars 22a, 22b, and 22c is achieved by the insulating holder 21 and the insulating resin layer 25. Thereby, an expensive insulating coating such as Teflon (R) becomes unnecessary, and the centralized power distribution member 17 can be manufactured relatively easily and at a low cost.
[0081]
(Another embodiment)
The embodiment of the present invention may be modified as follows.
In the embodiment, the plurality of positioning protrusions 82 are provided on the inner peripheral surface of the insulating holder 21, but a plurality of positioning protrusions 82 may also be provided on the outer peripheral surface. Then, when the insulating holder 21 is set in the insert molding die 70, the positioning protrusion 82 disposed on the outer peripheral surface of the insulating holder 21 is brought into contact with the inner wall surface of the lower die 71 or the upper die 72. Also good. Furthermore, the positioning protrusion 82 on the inner peripheral surface of the insulating holder 21 may be omitted and disposed only on the outer peripheral surface.
[0082]
In the above embodiment, the insulating holder 21 is composed of one member, but it may be composed of a plurality of arc-shaped resin parts having holding grooves 23a, 23b, 23c. In this case, the holding grooves 23a, 23b, and 23c of the respective arc-shaped resin parts are fitted into the bus bars 22a, 22b, and 22c to form the insulating holder 21 having a continuous annular shape as a whole. When insert molding is performed, the insulating holder 21 made of a plurality of arc-shaped resin members is set on the lower mold 71 of the insert molding die 70, and the insulating resin layer 25 is placed around the insulating holder 21 in the above-described process. Mold.
[0083]
In the above-described embodiment, the three-phase thin brushless motor 11 is embodied. However, the present invention is not limited thereto, and may be embodied in a single phase. In addition, with the realization of a single-phase motor, it is allowed to use two bus bars and holding grooves.
[0084]
-Although the said embodiment uses the thin DC brushless motor 11, implementation to an AC brushless motor is also permitted.
Next, in addition to the technical idea described in the claims, the technical idea grasped by the above-described embodiment will be described below.
[0085]
(1) In any one of claims 1 to 3, when insert molding is performed, the resin for forming the insulating resin layer is supplied into the cavity from the inside of the insulating holder, and the resin is supplied from a plurality of locations. According to this method, the resin for forming the insulating resin layer can be supplied into the cavity in a short time.
[0086]
(2) In the above (2), when supplying the resin for forming the insulating resin layer supplied into the cavity from a plurality of locations, the inner peripheral surface of the insulating holder is spaced at a certain interval in the inner peripheral direction of the insulating holder. Supply resin into the cavity toward According to this method, the pressure of the resin supplied into the cavity is evenly applied to the insulating holder. Therefore, when the resin is supplied, the insulating holder is not reliably displaced from the positioned position.
[0087]
(3) In any one of claims 1 to 3 and (1) and (2), the resin for forming the supplied insulating resin layer supplied to the cavity is the same PPS as the insulating holder. With this configuration, PPS can improve heat resistance and mechanical strength. In addition, by using the same material for the insulating holder and the insulating resin layer, the affinity between the two can be increased compared to the case where different materials are used in combination, and the insulating holder and the insulating resin layer are strong. Can be attached to.
[0088]
(4) In any one of claims 1 to 3 and (1) to (3), the resin for forming the supplied insulating resin layer supplied to the cavity has a color distinguishable from the forming material of the insulating holder. It is. With this configuration, it is possible to easily determine visually whether or not the insulating resin layer is completely covered on the entire concentrated power distribution member. As the color, for example, the supply insulating resin layer is preferably white and the insulating holder is preferably black so that there is a difference in brightness.
[0089]
【The invention's effect】
  According to the first aspect of the present invention, the concentrated power distribution member of the thin brushless motor for a vehicle excellent in waterproofness and dielectric strength can be manufactured relatively easily and reliably.In addition, since the insulating holder can be positioned and fixed at the initial stage of insert molding, it is possible to reliably prevent the insulating holder from inadvertently tilting before supplying the resin into the cavity.
[0090]
  According to invention of Claim 2,Even after the cavity is filled with resin to some extent and both supports are retracted, the positioning of the insulating holder can be continued. Therefore, it is possible to more reliably prevent the insulating holder from being displaced during insert molding.
[0091]
  According to invention of Claim 3,In the state in which the lower mold side support is protruded, the distal end of the lower mold side support is engaged with the non-penetrating recess provided in the insulating holder, so that the displacement of the insulating holder can be prevented. Therefore, since the insulating holder can be held at a predetermined position in the cavity, the synthetic resin can be coated with a uniform thickness around the insulating holder.
[Brief description of the drawings]
FIG. 1 is a schematic view of a thin brushless motor.
FIG. 2 is a schematic wiring diagram of a thin brushless motor.
FIG. 3 is a perspective view of a central power distribution member.
FIG. 4 is a front view of a concentrated power distribution member.
FIG. 5 is a rear view of the concentrated power distribution member.
6A is a cross-sectional view of a concentrated power distribution member, FIG. 6B is an enlarged view of the terminal portion, and FIG. 6C is an enlarged perspective view of the terminal portion.
FIG. 7 is a plan view showing a terminal portion of the concentrated power distribution member.
FIG. 8 is a perspective view of an insulating holder.
FIG. 9 is a front view in which a bus bar is inserted into an insulating holder.
FIG. 10 is an enlarged front view showing a part of the insulating holder.
FIG. 11 is a front view showing only a bus bar without an insulating holder.
FIG. 12 is an enlarged view showing a bus bar non-accommodating portion in the insulating holder.
13A is an EE cross-sectional view in FIG. 9, FIG. 13B is an FF cross-sectional view in FIG. 9, and FIG. 13C is a GG cross-sectional view in FIG.
14A is a cross-sectional view taken along line AA of FIG. 4, and FIG. 14B is a perspective view of the portion.
15A is a cross-sectional view taken along line BB in FIG. 4, and FIG. 15B is a perspective view of the portion.
16A is a cross-sectional view taken along the line CC of FIG. 4, and FIG. 16B is a perspective view of the portion.
17A is a DD cross-sectional view of FIG. 4, and FIG. 17B is a perspective view of the portion.
18A is a cross-sectional view of the first pressing apparatus with the mold opened, and FIG. 18B is a band-shaped molding material that is press-molded there.
FIG. 19A is a cross-sectional view of the first press device with the mold closed, and FIG. 19B is a strip-shaped molding material press-molded there.
20A is a cross-sectional view of the second press device with the mold closed, and FIG. 20B is a band-shaped molding material press-molded there.
FIG. 21A is a band-shaped molding material before bending a terminal portion of a bus bar, and FIG.
FIG. 22 is a rear view of the insulating holder.
23A is an enlarged view of a non-penetrating recess, and FIG. 23B is an enlarged perspective view of the non-penetrating recess.
FIG. 24 is a cross-sectional view showing a state where an insert holder is set and an insulating holder is set.
FIG. 25 is a cross-sectional view showing a state in which a molten resin material is filled in an insert molding die following FIG. 24;
FIG. 26 is a cross-sectional view showing a state where the holder support pin and the upper mold side support are retracted, following FIG. 25;
FIG. 27 is a cross-sectional view showing a state where the insert molding die is opened following FIG. 26;
FIG. 28 is a view showing a manufacturing process of the concentrated power distribution member, in which a conductive metal plate material is punched to obtain a band-shaped molding material.
FIG. 29 is a view showing the manufacturing process subsequent to FIG. 28, wherein the terminal portion of the bus bar is bent.
30 is a view showing the manufacturing process subsequent to FIG. 29, in which a bus bar is inserted into an insulating holder. FIG.
FIG. 31 is a view showing the manufacturing process subsequent to FIG. 30, wherein the tab of the bus bar is bent inward;
32 is a view showing the manufacturing process subsequent to FIG. 31, in which part of the terminal portion is sealed with a sealing material; FIG.
[Explanation of symbols]
DESCRIPTION OF SYMBOLS 11 ... Thin brushless motor (motor), 15 ... Stator, 16 ... Winding, 17 ... Concentrated power distribution member, 21 ... Insulation holder, 22a, 22b, 22c ... Bus bar, 23a, 23b, 23c ... Holding groove, 25 ... Insulating resin Layers, 41a, 41b, 41c ... tabs, 43a-43d ... walls, 50u, 50v, 50w ... terminal parts, 70 ... molds for insert molding, 71 ... lower molds, 72 ... upper molds, 73 ... cavities, 74 ... Holder support (holder support pin), 80 ... upper mold side support, 82 ... positioning protrusion (positioning part).

Claims (3)

A plurality of bus bars provided with terminal portions connected to the battery and tabs connected to the stator windings, and corresponding to each phase of the motor, and holding grooves for holding the bus bars at predetermined intervals And an insulating resin layer that is formed by insert molding and covers each of the bus bars and the insulating holder, and a ring-shaped concentrated power distribution member that can distribute current to the windings in a concentrated manner. A manufacturing method,
When the insulating holder holding each bus bar is placed in the cavity of the insert molding die, the upper surface side of the insulating holder protrudes from the upper mold inner wall surface, and the upper edge of the wall portion constituting the holding groove and Both upper end edges of each bus bar are supported by an upper mold side support body having a cross-sectional shape that can be pressed , and the bottom surface side is supported by a lower mold side support body projecting from the inner wall surface of the lower mold. A thin vehicle for the vehicle characterized in that the insulating holder is floated in the cavity while insert molding is performed by retracting the both supports while supplying the resin for molding the insulating resin layer into the cavity. A method for manufacturing a centralized power distribution member of a brushless motor. The concentration of the thin brushless motor for a vehicle according to claim 1, wherein the insulating holder is provided with a positioning portion that contacts the inner wall surface of the lower mold during insert molding to position and fix the insulating holder. A method for manufacturing a power distribution member. The rib is surrounded by a rib projecting from the bottom surface of the insulating holder, and a non-penetrating recess having a notch is formed in the rib. When placing, the tip of the lower mold side support projectingly provided on the inner wall surface of the lower mold is engaged with the recess, and in this state, the resin for forming the insulating resin layer is supplied into the cavity. The manufacturing method of the concentrated power distribution member of the thin brushless motor for vehicles of Claim 1 characterized by the above-mentioned.

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