JP7503378B2 - motor - Google Patents

Description

The present invention relates to a motor.

When assembling a stator by winding a coil around the stator core of a motor, a technique is known in which the conductor wire drawn from the coil is electrically connected to a connection part provided on a substrate or the like.

JP 2009-225572 A JP 2019-161745 A

In motors and other devices, heat-resistant resins are sometimes used for the insulating coating that covers the conductors of the coils. When connecting conductors coated with such heat-resistant resins to terminals, ordinary soldering does not have enough processing temperature to melt the insulating coating. For this reason, a fusing process (sometimes referred to as "thermal crimping process") may be used, in which an electric current is passed through the metallic connection to generate heat, exposing the conductor from the insulating coating and enabling electrical conduction with the terminal, or resistance welding may be used, in which the metal part of the connection and the conductor are melted and bonded.

The connection part is electrically connected to wiring formed on a substrate or the like. When the connection part is subjected to a thermal crimping process or a resistance welding process, heat is transferred from the connection part to the wiring, and a large stress is also applied to the connection part. For example, if the connection part and the wiring are joined with solder, the conducted heat may cause the solder to melt. In this case, the stress acting on the connection part may cause the connection part to move from the attachment position of the conductor, which may result in the electrical connection between the conductor and the wiring being severed.

In one aspect, the objective is to provide a motor that can prevent electrical connection from being disconnected.

A motor according to one aspect of the present invention includes a stator having a coil, a lead wire drawn from the coil in the axial direction, a substrate provided with wiring electrically connected to the lead wire, and a connector having a first connection portion electrically connected to the lead wire and a second connection portion electrically connected to the wiring . The substrate is located between the stator and the connector in the axial direction. A portion of the lead wire is fused or welded to a surface of the first connection portion extending in the axial direction. The connector is positioned relative to the wiring and provided on the substrate. The second connection portion is in contact with a surface of the wiring.

According to one embodiment, it is possible to prevent electrical connections from being disconnected.

FIG. 1 is a perspective view illustrating an example of a motor before a connector is disposed in an embodiment. FIG. 2 is a perspective view illustrating an example of a connector according to the embodiment. FIG. 3 is a perspective view illustrating an example of a connection plate on which connectors are arranged in the embodiment. FIG. 4 is a perspective view showing an example of a connector according to the first modified example. FIG. 5 is a perspective view showing an example of a connection plate on which connectors are arranged in the first modified example. FIG. 6 is a perspective view showing an example of a connector according to the second modified example.

The motor according to the embodiment will be described below with reference to the drawings. Note that the dimensional relationships and ratios of each element in the drawings may differ from reality. The drawings may also include parts with different dimensional relationships and ratios. To make the description easier to understand, each drawing may show a coordinate system that includes at least one of the axial, radial, and circumferential directions of the stator 2.

Figure 1 is a perspective view showing an example of a motor before a connector is arranged in the embodiment. As shown in Figure 1, the motor 1 in the embodiment includes, for example, a stator 2, a frame 3, a rotor 4, a rotating shaft (shaft) 5, and a connection plate 20. The stator 2 is housed, for example, inside the frame 3. Note that the stator 2 described in the embodiment is a stator in an inner rotor type brushless motor, and for example, a rotor 4 having a magnet as a component is arranged on the inner periphery of the stator 2, and further, a rotating shaft (shaft) 5 is coupled to this rotor 4. The motor 1 in which the stator 2 is mounted is used, for example, as an in-vehicle motor.

The stator 2 includes a stator core 2a, an insulator 2b, and a coil 30. The stator core 2a is formed by stacking a predetermined number of steel cores made of a soft magnetic material such as silicon steel in the axial direction. The stator core 2a has a plurality of teeth 2c extending radially from the annular portion toward the rotor 4. In this embodiment, the stator core 2a has, for example, 12 teeth 2c, but the number is not particularly limited. Each tooth 2c is arranged at equal angular intervals in the circumferential direction of the annular portion, and the tip of each tooth 2c has a tip portion that spreads out in the circumferential direction.

The insulator 2b covers the stator core 2a (described later) from both axial sides so as to cover the stator 2. The insulator 2b is formed, for example, by injection molding using an insulating resin. A connecting plate 20 is provided on the insulator 2b.

As shown in FIG. 1, a coil 30 is wound around each tooth 2c via an insulator 2b. A conductor 31 drawn from the coil 30 extends upward (in the positive axial direction) and is electrically connected to a connector 10 disposed on the connection plate 20, as described later. In this embodiment, a heat-resistant resin such as polyimide is used as an insulating coating that covers the conductor 31. The conductor 31 in this embodiment is, for example, a round copper wire with a thickness of 1 mm or more. The conductor 31 is an example of a lead wire drawn from a coil.

The connection plate 20 is, for example, a substrate for electrically connecting the conductors 31 drawn from the coils 30 to each other. The connection plate 20 is provided with wiring 21 and insertion holes 22. The wiring 21 is wiring that electrically connects the multiple conductors 31 to each other, and is formed of, for example, copper foil. The insertion holes 22 are holes through which the conductors 31 drawn from the coils 30 are inserted. The connection plate 20 is an example of a substrate.

In this embodiment, the conductor 31 and the wiring 21 are electrically connected, for example, via a connector 10 arranged on the connection plate 20. FIG. 2 is a perspective view showing an example of a connector in this embodiment. As shown in FIG. 2, the connector 10 in this embodiment includes a first connection portion 11, a second connection portion 12, claw portions 13a and 13b, and an opening 14. The connector 10 is formed from a single member using a metal material such as copper.

The first connection part 11 is electrically connected to the conductor 31. The conductor 31 drawn from the coil 30 is inserted, for example, into the recess 11a of the first connection part 11. The insulating coating of the conductor 31 is then removed, for example, by thermal crimping, and the conductor 31 is welded to the first connection part 11. FIG. 3 is a perspective view showing an example of a connection plate in which a connector is arranged in an embodiment. Note that FIG. 3 shows a state in which the conductor 31 is inserted into the recess 11a of the first connection part 11 in the portion shown in frame F in FIG. 1, before the first connection part 11 and the conductor 31 are subjected to thermal crimping. The thermal crimping is performed, for example, by passing a high current through the recess 11a of the first connection part 11 in the state shown in FIG. 3 to generate heat, and then applying a pressure of about 10 to 20 N from both radial sides of the recess 11a to crush the conductor 31 inserted into the recess 11a.

The second connection portion 12 is electrically connected to the wiring 21 of the connection plate 20. As shown in FIG. 3, the second connection portion 12 is joined, for example, by soldering while in contact with the wiring 21. This electrically connects the conductor 31 connected to the first connection portion 11 and the wiring 21 connected to the second connection portion 12 via the connector 10.

The claws 13a and 13b are engagement parts that engage with the connection plate 20. As shown in FIG. 3, the claws 13a and 13b, for example, engage with first openings 23a and 23b, respectively, provided in the connection plate 20. This positions the connector 10 relative to the wiring 21 provided on the connection plate 20.

The opening 14 becomes a screw hole when the connector 10 is screwed to the connection plate 20. As shown in FIG. 3, the connector 10 is engaged with the connection plate 20 by screwing the opening 14 into the second opening 24 of the connection plate 20 with a screw 50.

In the thermal crimping process, when the first connection portion 11 generates heat, the heat is also conducted to the second connection portion 12. This may cause the solder joining the second connection portion 12 and the wiring 21 to melt. In this case, stress may be applied to the first connection portion 11 during the thermal crimping process, causing the connector 10 to move and the electrical connection with the wiring 21 to be cut off. On the other hand, in this embodiment, as shown in FIG. 3, the connector 10 is engaged with the connection plate 20 via the claw portions 13a and 13b and the screw 50 screwed into the opening 14. This prevents the connector 10 from moving even when stress is applied to the first connection portion 11, thereby preventing the electrical connection between the conductor 31 connected to the first connection portion 11 and the wiring 21 connected to the second connection portion 12 from being cut off.

Next, modified examples of the motor 1 equipped with the connector 10 of this embodiment will be described. FIG. 4 is a perspective view showing an example of a connector in the first modified example. FIG. 5 is a perspective view showing an example of a connection plate on which the connector in the first modified example is arranged. As shown in FIG. 4, the connector 70 in the first modified example includes a first connection portion 71, a second connection portion 12, and claw portions 13a and 13b. The connector 70 is also formed from a single member using a metal material such as copper. In each of the modified examples below, the same reference numerals are used to designate the same parts as those shown in the drawings described above, and duplicated explanations will be omitted.

As shown in FIG. 4, the shape of the first connection portion 71 of the connector 70 in the first modified example is different from the shape of the first connection portion 11 of the connector 10 in the embodiment. As shown in FIG. 5, in the first modified example, the conductor 91 drawn out from the coil 30 is fixed to the back portion 71a of the first connection portion 71 of the connector 70 by, for example, resistance welding. The conductor 91 is, for example, a rectangular wire made of copper.

As shown in FIG. 4, the connector 70 in the first modified example differs from the connector 10 in the embodiment in that it does not have an opening 14. In this case, the connector 70 engages with the connection plate 20 via the claws 13a and 13b.

In the resistance welding, the first connection portion 71 of the connector 70 becomes hot, and stress is applied to the first connection portion 71. In this case, the solder joining the second connection portion 12 and the wiring 21 may melt due to heat being conducted to the second connection portion 12 of the connector 70. In this case, the connector 70 may move due to stress being applied to the first connection portion 71 during the resistance welding, and the electrical connection with the wiring 21 may be cut off. On the other hand, in the first modified example, as shown in FIG. 5, the connector 70 is engaged with the connection plate 20 via the claw portions 13a and 13b. As a result, even if stress is applied to the first connection portion 71, the connector 10 can be prevented from moving, and the electrical connection between the conductor 91 connected to the first connection portion 71 and the wiring 21 connected to the second connection portion 12 can be prevented from being cut off.

Figure 6 is a perspective view showing an example of a connector in the second modified example. As shown in Figure 6, the connector 80 in the second modified example includes a first connection portion 11, a second connection portion 12, claw portions 13a and 13b, and a protrusion 84. The connector 80 is also formed from a single member using a metal material such as copper.

The connector 80 in the second modified example differs from the connector 10 in the embodiment in that it has a protrusion 84 instead of the opening 14. The protrusion 84 of the connector 80 is a portion that protrudes downward (in the negative axial direction) from a portion of the connector 80 sandwiched between the first connection portion 11 and the second connection portion 12. The protrusion 84 is fitted into, for example, a recess (not shown) provided in the connection plate 20. That is, the connector 80 in the second modified example engages with the connection plate 20 via the claw portions 13a and 13b and the protrusion 84. As a result, in the second modified example, there is no need to use the screw 50, and therefore the number of parts can be reduced compared to the embodiment.

Although the embodiments and modifications of the present invention have been described above, the present invention is not limited to the above embodiments and modifications, and various modifications are possible without departing from the spirit of the present invention. For example, the configuration in which the conductor 31 is fused to the connector 10 and the configuration in which the conductor 91 is welded to the connector 70 have been described, but the method of connecting the lead wire and the connector is not limited to this, and for example, the conductor 91 may be joined to the connector 70 by soldering.

The connector 70 may also be configured to have an opening 14 and a protrusion 84. By engaging the connector 70 with the connection plate 20 via the screw 50 and the protrusion 84 in addition to the claws 13a and 13b, the resistance to stress at the engagement portion between the connector 70 and the connection plate 20 can be strengthened.

The connector 10 may also be configured not to have the claw portions 13a and 13b. Even in this case, the connector 10 is engaged with the connection plate 20 by being screwed to the connection plate 20 by the screw 50 through the opening 14. In this case, since it is not necessary to provide the first openings 23a and 23b corresponding to the claw portions 13a and 13b in the connection plate 20, the man-hours required to process the connection plate 20 can be reduced.

In this way, the shapes of the connectors 10, 70, and 80 and the method of connecting the conductor 31 or 91 to the connector 10, 70, or 80 may be changed as appropriate, taking into consideration the magnitude of stress on the first connection portion 11, 71, the processing cost of the connection plate 20, the number of parts required, etc. For example, the connection plate 20 may have a claw portion that engages with the connector 10, or the claw portions 13a, 13b of the connector 10 and the claw portions provided on the connection plate 20 may be configured to engage with each other.

Furthermore, the present invention is not limited to the above-mentioned embodiment. The present invention also includes configurations in which the above-mentioned components are appropriately combined. Further modifications can be easily derived by those skilled in the art. Therefore, the broader aspects of the present invention are not limited to the above-mentioned embodiment, and various modifications are possible.

1 motor, 2 stator, 3 frame, 4 rotor, 5 shaft, 10, 70, 80 connector, 11, 71 first connection part, 12 second connection part, 13a, 13b claw part, 14 opening, 84 protrusion, 20 connection plate, 21 wiring, 30 coil, 31, 91 conductor

Claims (7)

a stator having a coil;
A lead wire drawn from the coil in an axial direction;
A substrate provided with wiring electrically connected to the lead-out line;
a connector having a first connection portion electrically connected to the lead wire and a second connection portion electrically connected to the wiring ;
Equipped with
the substrate is located between the stator and the connector in the axial direction;
A portion of the lead wire is fused or welded to a surface of the first connection portion extending in the axial direction,
the connector is positioned relative to the wiring and is provided on the board ;
The second connection portion is in contact with a surface of the wiring .
motor. The motor of claim 1, wherein the connector is engaged with the substrate. a stator having a coil;
A lead wire drawn from the coil in an axial direction;
A substrate provided with wiring electrically connected to the lead-out line;
a connector having a first connection portion electrically connected to the lead wire and a second connection portion electrically connected to the wiring;
Equipped with
the substrate is located between the stator and the connector in the axial direction;
A portion of the lead wire is fused or welded to a surface of the first connection portion extending in the axial direction,
the connector is positioned relative to the wiring and is provided on the board;
The connector includes a tab portion that engages with a portion of the substrate .
motor . The motor according to claim 2 or 3, wherein at least a portion of the connector is fitted or screwed to the board. The motor according to any one of claims 1 to 4, wherein the connector is formed of a metal member. A portion of the lead wire is electrically connected to the first connection portion by resistance welding or thermal crimping.
6. A motor according to claim 1. 7. The motor according to claim 1, wherein the connector is formed from a single member.

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