JPH0622527A - Brushless motor - Google Patents

Abstract

PURPOSE:To reduce the manhour in assembling and the number of parts by stacking an insulating layer and a conductor pattern directly on one side of a bracket body made of a thin metallic plate, and uniting them, and then, processing them plastically into a solid shape. CONSTITUTION:A insulating layer 4 is formed on a metallic plate in the shape of a plate being the base material of a bracket body 2, and then a conductor pattern 5 is printed, and a specified wiring circuit is drawn. Furthermore, a cover layer 6 is stacked for insulation treatment on the conductor pattern 5, and sections corresponding to a wiring circuit part and a lead part are made. Sections corresponding to a motor mounting part and an end for connection are made by die-cutting the metallic plate of the bracket body 2 united with this laminate 3. Next, a bracket is completed by molding the die-cut bracket body 2 into a solid shape by press processing. Hereby, the work of sticking the circuit board to the bracket body 2 can be omitted, and the number of parts can also be reduced.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a brushless motor.

[0002]

2. Description of the Related Art In a conventional brushless motor, as shown in FIGS. 8 and 9, a bracket main body a and a flexible circuit board d having a conductor pattern c interposed between two flexible films b and b. And (4) are separately manufactured, and the strip-shaped lead portion f of the flexible circuit board d is inserted into the hole e of the bracket body a (as shown by the phantom line in FIG. 8) to form an annular shape of the flexible circuit board d. It was necessary to attach the wiring circuit portion g to the bottom surface portion h of the bracket body a via the adhesive layer i.

[0003]

However, it is difficult to automate such work, and it is necessary to rely on manual work. Therefore, it takes a lot of time and effort to assemble the motor.

Therefore, an object of the present invention is to provide a brushless motor which solves the above-mentioned conventional problems.

[0005]

In the brushless motor of the present invention, in order to achieve the above object, a conductive pattern is laminated on one surface of a bracket body made of a thin metal plate through an insulating layer, and the insulating layer, This is provided with a bracket in which the conductor pattern and the bracket body are formed into an integral three-dimensional shape by plastic working.

[0006]

[Function] Since the insulating layer (corresponding to the conventional flexible circuit board) and the conductor pattern are directly laminated and integrated on one surface of the bracket body (to the bracket body of the flexible circuit board which has been conventionally required) It is possible to reduce the number of assembling steps (by omitting the work such as sticking) and to reduce the number of parts because the insulating layer is also used as the adhesive layer.

[0007]

The present invention will be described in detail below with reference to the drawings showing the embodiments.

FIG. 1 shows an embodiment of a brushless motor according to the present invention, in which reference numeral 1 denotes a bracket, which is a thin metal plate-made bracket main body 2 and is laminated on one surface of the bracket main body 2. It is composed of the integrated wiring laminated film body 3.

This laminated film body 3 has elasticity, and is shown in FIGS.
As shown in FIG. 2, the insulating layer 4, the conductor pattern 5 made of copper foil, and the insulating coating layer 6 are formed and sequentially laminated on a part of the surface 7 of the bracket body 2.

A land portion 9 is formed by removing the coating layer 6 to expose the conductor pattern 5 at a predetermined portion of the wiring circuit portion 8 (semicircular shape in the figure) of the sheet body 3, and further. At the outer end of the strip-shaped lead portion 10 of the sheet body 3, a connector connecting portion 11 is formed by removing the coating layer 6 to expose the conductor pattern 5.

Further, as shown in FIG. 1, a mounting hole corresponding portion 12 is formed in the bracket main body 2 by burring or the like, and one end portion of a shaft 13 is inserted into the mounting hole corresponding portion 12 and caulked. It is fixed by.

A stator 14 composed of a stator core and a stator coil is fixed to the outer peripheral surface of the shaft 13, and a stator coil lead wire 15 of the stator 14 is connected to the land portion 9 by soldering or the like.

Reference numeral 16 denotes a hub. An annular rotor magnet 17 is fixed to the inner peripheral edge of the hub 16 (the lower part of the drawing), and the outer peripheral surface of the stator 14 and the inner peripheral surface of the rotor magnet 17 have a minute predetermined distance. Face to face.

The hub 16 includes a shaft 13 via bearings 18, 18.
Is rotatably pivotally attached to the stator, and a control current sent through the laminated film body 3 and the stator coil lead wire 15 ...
The hub 16 rotates in a predetermined direction by exciting 14 and rotating relative to the rotor magnet 17.

As shown in FIG. 2, the bracket body 2 has a shallow plate-shaped motor mounting portion 19 and a motor mounting portion 19.
And a plate-shaped connecting end portion 20 extending radially outwardly from the bottom surface portion 21 of the motor mounting portion 19 or almost the entire surface--in the illustrated example, the bottom surface portion 21 It is formed so as to correspond to a part, a part of the peripheral wall part 22 of the motor mounting part 19, a part of the flange part 23 of the motor mounting part 19, and the connecting end part 20.

The connecting end 20 is formed into a shape that can be inserted into the connector 24, and the connector connecting portion 11 is provided corresponding to the connecting end 20. As a result, the connector 24 and the conductor pattern 5 of the laminated film body 3 can be connected.

As described above, since the connector connecting portion 11 is projected on the outside of the motor while being held on the connecting end portion 20, it is not necessary to provide a connector on its own, and the connector 24 is connected ( It is easy to attach and can easily be electrically connected to an external power source.

In addition, as in the case of the pasted type, the strip-shaped lead portion 10 may peel off from the bracket main body 2 with the lapse of time and float up to come into contact with the hub 16 or the rotor magnet 17, or the like. It can be prevented.

Next, a method of manufacturing the bracket 1 will be described with reference to FIGS. 4 and 5.

First, as shown in (A1) of FIG. 4 and (A2) which is an enlarged sectional view of an essential part of (A1), and (A) of FIG.
After forming an insulating layer 4 for insulating treatment on a flat metal substrate 25 such as an aluminum plate or an iron plate as a material of the bracket body 2, a conductor pattern 5 is formed by printing by photoetching or the like, and a predetermined wiring is formed. Draw a circuit. Further, a coating layer 6 for insulation treatment is laminated on the conductor pattern 5 to form a portion corresponding to the wiring circuit portion 8 and the lead portion 10.

In this way, the laminated film body 3 (wiring circuit portion 8
Then, the metal substrate 25 in which the lead portion 10) and the lead portion 10) are laminated and integrated is punched as shown in FIGS. 4B and 5B, and the motor mounting portion 19 and the connecting end portion are formed. Form a part corresponding to 20.

Further, the stamped bracket body 2 (motor mounting portion 19 and connecting end portion 20) is pressed to
As shown in (C) of FIG. 4 and (C) of FIG.
And the connecting end portion 20), the bracket 1 is completed.

As described above, since the laminated film body 3 is laminated on the flat metal substrate 25, various processes such as insulation and printing are easy, and the manufacture of the bracket 1 can be automated.

As a result of the experiment, during the press working, the conductor pattern 5 (see FIG. 3) of the laminated film body 3 was not damaged, sufficient continuity was secured, and the reliability against cracks, disconnection, etc. was secured. It has been confirmed that there are no problems.

Next, FIG. 6 shows a case where the laminated film body 3 is formed on the back surface 26 of the bracket body 2, and in this case as well, the bracket 1 can be manufactured in the same manner as in the above-mentioned embodiment.

In this embodiment, unlike the embodiment shown in FIG. 1, the laminated film body 3 is provided on the back surface 26 of the bracket main body 2, that is, on the outside of the motor. Therefore, the electric connection (for example, soldering) of the coil wire derived from the stator 14 can be performed from the outside of the motor, which can be easily performed even if the motor is downsized and the workability can be improved. .

Further, in FIG. 6, connection terminals 27 such as pins (connected to the stator coil of the stator 14) can be connected to the land portion 9 of the laminated film body 3 as shown in FIG.

Specifically, a through hole for inserting the connecting terminal 27 is formed in the laminated film body 3 and the bracket main body 2, and the connecting terminal 27 is inserted through the through hole from the surface 7 side of the bracket main body 2. The tip of the connecting terminal 27 is projected to the land portion 9 by a predetermined amount, and the projecting tip is connected to the conductor pattern 5 by soldering or the like.

[0029]

Since the present invention is constructed as described above, it has the following great effects.

Since the insulating layer 4 (corresponding to a conventional flexible circuit board) and the conductor pattern 5 are directly laminated and integrated on one surface of the bracket body 2, The number of assembly steps can be reduced by omitting the work such as attaching to the bracket body, and the number of parts can be reduced because the insulating layer 4 is also used as the adhesive layer.

[Brief description of drawings]

FIG. 1 is an enlarged sectional front view showing an embodiment of the present invention.

FIG. 2 is a perspective view of a bracket.

FIG. 3 is an enlarged sectional view of an essential part showing a state in which a laminated film body is laminated on a bracket body.

FIG. 4 is a cross-sectional view for explaining the method of manufacturing the bracket.

FIG. 5 is a plan view for explaining the method of manufacturing the bracket.

FIG. 6 is an enlarged sectional front view showing a modified example.

FIG. 7 is an enlarged sectional view of an essential part showing a connection state between a connection terminal and a conductor pattern.

FIG. 8 is a perspective view showing a conventional example.

FIG. 9 is an enlarged cross-sectional view of a main part of a conventional example.

[Explanation of symbols]

 1 bracket 2 bracket body 4 insulating layer 5 conductor pattern

Claims (1)

[Claims] 1. A conductive pattern 5 is laminated on one surface of a thin metal bracket body 2 with an insulating layer 4 interposed therebetween, and
A bracket 1 in which the insulating layer 4, the conductor pattern 5 and the bracket body 2 are formed into a one-dimensional shape by plastic working is
A brushless motor characterized by being equipped.