Vehicle-mounted brushless motor device and manufacturing method thereof

Abstract

Technical problem: Provided is a vehicle-mounted brushless motor device that can be miniaturized relative to the axial direction of a rotor and a method for manufacturing the same. Solution: A vehicle-mounted brushless motor device (1) includes a brushless motor (10) and an electronic substrate (30), wherein the brushless motor (10) includes a rotor (12) and a stator (16) including a plurality of coils (18) arranged around the rotor (12). The electronic substrate (30) includes: a substrate body (32) including a through hole (34) penetrating in the axial direction (X) of the rotor (12) and arranged on the opposite side of the output shaft of the brushless motor (10) along a plane (P) intersecting the axial direction (X); and a terminal (40) fixed to a surface of the substrate body (32) on the opposite side of the rotor (12). The coil wire (20) of the coil (18) is inserted through the through hole (34) and is welded to the terminal (40) on the opposite side of the rotor (12) via the substrate body (32).

Description

Technical Field

[0001] The present disclosure relates to a vehicle-mounted brushless motor device and a method for manufacturing the same. Background Art

[0002] In recent years, various brushless motors that do not use mechanical contacts such as brushes or switches have been developed. For example, Patent Document 1 discloses a structure related to a pump device including a brushless motor.

[0003] Prior art literature

[0004] Patent Literature

[0005] Patent Document 1: Japanese Patent Application Publication No. 2017-15002 Summary of the invention

[0006] 1. Technical issues to be resolved

[0007] However, in an electric actuator mounted on a vehicle, the miniaturization of the device is desired due to the space limitation of the assembly position of the electric actuator. However, in the pump device described in Patent Document 1, the driving coil and the circuit substrate are connected via the terminal pins arranged along the axial direction of the rotor by soldering the other end of the terminal pin electrically connected to the driving coil to the circuit substrate. Therefore, in the axial direction of the rotor, in addition to the space for arranging the terminal pins, it is also necessary to ensure the space for soldering the terminal pins to the circuit substrate, making it difficult to miniaturize the pump device as a whole in the axial direction of the rotor. Patent Document 1 does not disclose any solution for solving such a problem.

[0008] In view of the above circumstances, an object of at least one embodiment of the present disclosure is to provide a vehicle-mounted brushless motor device that can be miniaturized in the axial direction of a rotor, and a method for manufacturing the same.

[0009] (II) Technical solution

[0010] (1) A vehicle-mounted brushless motor device according to at least one embodiment of the present invention includes a brushless motor and an electronic substrate, wherein:

[0011] The brushless motor includes a rotor and a stator including a plurality of coils arranged around the rotor.

[0012] Electronic substrates include:

[0013] a substrate body having a through hole formed therein and penetrating in the axial direction of the rotor and arranged on the opposite side of the output side of the brushless motor along a plane intersecting the axial direction; and

[0014] The terminal is fixed to the surface of the substrate body on the opposite side of the rotor,

[0015] The coil wire of the coil is inserted into the through hole and is welded to the terminal on the opposite side of the rotor via the substrate body.

[0016] (2) In some embodiments, in the structure of (1) above, a first slit extending along a first direction included in the plane may be formed on the terminal,

[0017] The terminal contains:

[0018] A first terminal portion, which is arranged on one side across a first slit;

[0019] A second terminal portion, which is disposed on the other side across the first slit;

[0020] a third terminal portion connecting the first terminal portion and the second terminal portion; and

[0021] a protrusion that is arranged to protrude from the second terminal portion toward the opposite side of the rotor in the axial direction,

[0022] The protrusion is welded to the coil wire.

[0023] The first terminal portion is connected to the substrate body via a first soldering portion.

[0024] (3) In some embodiments, in the structure of (2) above, the second terminal portion may be connected to the substrate body via a second soldering portion.

[0025] The first soldering portion is separated from the second soldering portion.

[0026] (4) In some embodiments, in the structure of (2) or (3) above, the third terminal portion may be connected to one end of the second terminal portion in the first direction,

[0027] The protruding portion is connected to the other end portion of the second terminal portion in the first direction.

[0028] (5) In some embodiments, in any one of the structures (2) to (4) above, the protrusion may include a hook portion, and the hook portion may be formed in a hook shape and welded to the coil wire by fusion.

[0029] (6) In some embodiments, in any one of the structures (2) to (5) above, the length of the second terminal portion in the first direction may be longer than the length of the first terminal portion in the first direction.

[0030] (7) In some embodiments, in the structure of (3) above, the electronic substrate may include:

[0031] a metal foil terminal portion adjacent to the through hole and arranged along a surface of the substrate body on the opposite side to the rotor; and

[0032] The protective layer is disposed on the metal foil terminal portion and has a first opening corresponding to the first soldering portion and a second opening corresponding to the second soldering portion.

[0033] A second slit extending in the first direction is formed on the metal foil terminal portion,

[0034] The metal foil terminal section includes:

[0035] A first portion, which is disposed on one side across the second slit and connected to the first soldering portion at the first opening;

[0036] A second portion, which is disposed on the other side across the second slit and connected to the second soldering portion at the second opening;

[0037] A third part connects the first part to the second part.

[0038] (8) In some embodiments, in the structure of (7) above, the area of ​​the second portion may be larger than the area of ​​the first portion.

[0039] (9) In some embodiments, in the structure of (8) above, the area of ​​the second portion may be at least 1.2 times the area of ​​the first portion.

[0040] (10) In some embodiments, in any one of the structures (1) to (9) above, the electronic substrate may include a plurality of terminals.

[0041] Each of the plurality of terminals is oriented in the same direction relative to the substrate body.

[0042] (11) In some embodiments, in any one of the structures (1) to (10) above, a retainer unit may be provided, the retainer unit including:

[0043] a connector terminal for connecting the electronic substrate to an external device; and

[0044] A holder is disposed between the substrate body and the brushless motor and supports the electronic substrate.

[0045] The electronic substrate includes a third soldering portion for connection to the connector terminal.

[0046] (12) In some embodiments, in the structure of (11) above, the holder may include a guide hole that penetrates the holder in the axial direction and guides the coil wire from the brushless motor side to the through hole of the substrate body.

[0047] (13) In some embodiments, in the structure of (12) above, the guide hole may include a tapered channel portion, and the tapered channel portion is formed such that a hole diameter becomes smaller as it moves away from the rotor in the axial direction.

[0048] (14) In some embodiments, in the structure of (12) or (13) above, a diameter of an opening end of the guide hole on the electronic substrate side may be smaller than a diameter of the through hole.

[0049] (15) A method for manufacturing a vehicle-mounted brushless motor device according to at least one embodiment of the present invention includes the following steps:

[0050] Arrange the substrate body of the electronic substrate on the opposite side of the output side of the brushless motor along a plane intersecting the axial direction of the rotor of the brushless motor;

[0051] Passing a coil wire of a coil constituting a stator of a brushless motor through a through hole of an electronic substrate; and

[0052] The coil wire is welded to the terminal on the opposite side of the rotor via the electronic substrate, and the terminal is fixed to the surface of the substrate body on the opposite side of the rotor.

[0053] (III) Beneficial effects

[0054] According to at least one embodiment of the present disclosure, it is possible to provide a vehicle-mounted brushless motor device that can be miniaturized in the axial direction of a rotor and a method for manufacturing the same. BRIEF DESCRIPTION OF THE DRAWINGS

[0055] Figure 1 This is a diagram schematically showing a configuration example of a vehicle-mounted brushless motor device according to an embodiment of the present disclosure.

[0056] Figure 2A It means in Figure 1 A partial enlarged view of region II indicated by a dotted line.

[0057] Figure 2B This is a diagram showing an example of the arrangement of magnets.

[0058] Figure 3 It is a plan view showing a structural example of a terminal in one embodiment.

[0059] Figure 4 It is a side view showing a structural example of a terminal in one embodiment.

[0060] Figure 5 It is a bottom view showing a structural example of a terminal in one embodiment.

[0061] Figure 6 It is a plan view schematically showing a configuration example of a terminal in one embodiment.

[0062] Figure 7 It is a perspective view schematically showing a metal foil terminal portion in one embodiment.

[0063] Figure 8 It is a perspective view schematically showing a first opening and a second opening of a protective layer in one embodiment.

[0064] Fig. 9 It is a perspective view schematically showing a state where a terminal in one embodiment is mounted on a substrate body.

[0065] Fig.10 It is a plan view schematically showing a structural example of a metal foil terminal portion in one embodiment.

[0066] Fig.11 It is a plan view schematically showing an upper region of an electronic substrate in one embodiment.

[0067] Fig.12 It is a side view schematically showing an upper region of an electronic substrate in one embodiment.

[0068] Fig.13 It is a schematic diagram which schematically shows the guide hole in one embodiment.

[0069] Fig.14 It is a diagram showing a modified example of the guide hole in one embodiment.

[0070] Fig.15 This is a flowchart showing a method for manufacturing a vehicle-mounted brushless motor device according to one embodiment.

[0071] Description of Reference Numerals

[0072] 1-brushless motor device for vehicle; 10-brushless motor; 12-rotor; 16-stator; 18-coil; 20-coil wire; 30-electronic substrate; 32-substrate body; 32A-upper surface; 34-through hole; 40-terminal; 41-first slit; 42-base; 43-first terminal portion; 44-second terminal portion; 44B-one end portion; 44C-other end portion; 45-third terminal portion; 47: hook portion; 50-holder unit; 52-holder; 54-guide hole; 55-motor side opening end; 56-substrate side opening Mouth end; 57-conical channel portion; 58-connector terminal; 58A-one end; 58B-the other end; 63-the third soldering portion; 70-metal foil terminal portion; 71-the first portion; 72-the second portion; 73-the second slit; 74-the third portion; 75-protective layer; 76-the first opening portion; 78-the second opening portion; 80-protrusion; 90-the first soldering portion; 92-the second soldering portion; L1-the length of the first terminal portion in the first direction a1; L2-the length of the second terminal portion in the first direction a1; P-plane; X-axial direction. DETAILED DESCRIPTION

[0073] Some embodiments of the present invention are described below with reference to the accompanying drawings. However, the scope of the present invention is not limited to the following embodiments. The dimensions, materials, shapes, and relative configurations of the structural components described in the following embodiments are not intended to limit the scope of the present invention to these, but are merely illustrative examples.

[0074] For example, expressions such as "in a certain direction", "along a certain direction", "parallel", "orthogonal", "center", "concentric" or "coaxial" that indicate relative or absolute configurations not only strictly indicate such configurations, but also indicate a state of relative displacement with a tolerance, or an angle or distance that can achieve the same degree of functionality.

[0075] For example, expressions such as “same”, “equal”, and “homogeneous” indicating that things are in an equal state not only indicate a strict equal state but also indicate a state in which there is a tolerance or a difference to the extent that the same function can be obtained.

[0076] For example, expressions indicating shapes such as a quadrilateral and a cylinder not only indicate shapes such as a quadrilateral and a cylinder in a strict geometric sense, but also indicate shapes including concave and convex portions, chamfered portions, etc. within a range that can obtain the same effect.

[0077] On the other hand, the expression “comprising,” “including,” “having,” “includes,” or “having” a constituent element is not an exclusive expression that excludes the presence of other constituent elements.

[0078] First, a schematic structure of a vehicle-mounted brushless motor device 1 according to an embodiment of the present disclosure will be described. Figure 1 1 is a diagram schematically showing a configuration example of a vehicle-mounted brushless motor device 1 according to an embodiment of the present disclosure. Figure 2A It means in Figure 1 A partial enlarged view of region II indicated by a dotted line.

[0079] like Figure 1 and Figure 2A As shown, the vehicle-mounted brushless motor device 1 can be applied as an electric oil pump (Electric Oil Pump: EOP), which is an electric oil supply device that is installed in a vehicle and supplies oil as lubrication, cooling or working fluid to an engine or a clutch, etc. The vehicle-mounted brushless motor device 1 includes: a brushless motor 10 that does not use mechanical contacts such as brushes and a change-over switch; and an electronic substrate 30 that controls the drive of the brushless motor 10.

[0080] The brushless motor 10 is an inner rotor type brushless motor, and includes, for example, a rotor 12 and a stator 16 including a plurality of coils 18 arranged around the rotor 12 .

[0081] The rotor 12 is arranged inside the stator 16, and is composed of an output shaft 14 (rotating shaft) arranged coaxially, a cylindrical rotor core (not shown) attached to the outer periphery of the output shaft 14, and an annular magnet 15 (see FIG. 1 ) fixed to the rotor core along the outer periphery of the rotor core and magnetized to multiple poles (for example, six poles). Figure 2B ).exist Figure 2B In the illustrated embodiment, the plate-shaped S-pole magnet portions 15a and the plate-shaped N-pole magnet portions 15b are alternately arranged in the circumferential direction, and the six magnet portions 15a and 15b (three magnet portions 15a and three magnet portions 15b) are arranged to form a substantially hexagonal shape when viewed in the axial direction of the rotor 12. A pump rotor (not shown) such as a gear (not shown) for conveying oil is connected to the output shaft 14 in a manner that allows rotation together with the output shaft 14.

[0082] Hereinafter, the axial direction of the rotor 12 is described as “axial direction X”. In addition, the direction from the electronic substrate 30 toward the brushless motor 10 (the direction from the opposite side of the output side of the brushless motor 10 toward the output side of the brushless motor 10) in the axial direction X is described as “downward” or simply “downward”, and the direction from the brushless motor 10 toward the electronic substrate 30 (the direction from the output side of the brushless motor 10 toward the opposite side of the output side of the brushless motor 10) in the axial direction X is described as “upward” or simply “upward”.

[0083] The stator 16 includes a housing (motor housing) 4 which also serves as a yoke, a plurality of stator cores (core members) 5 fixed to the inner circumference of the housing 4, and a plurality of coils 18 respectively wound around the plurality of stator cores 5. The housing 4 is formed into a bottomed cylindrical shape by a metal such as iron. A retainer unit 50 (described later) made of, for example, synthetic resin is mounted on the opening of the housing 4. An electronic substrate 30 is mounted on the upper portion of the retainer unit 50, and the upper portion of the electronic substrate 30 is covered by a top cover 2. The housing 4, the retainer unit 50, and the top cover 2 are fixed by bolts 6. Each coil 18 is formed by winding a conductive metal wire such as copper around the stator core 5 multiple times.

[0084] The electronic substrate 30 includes: a substrate body 32, which is arranged on the opposite side of the output side of the brushless motor 10 along a plane P intersecting the axial direction X; and a terminal 40, which is fixed to the surface on the opposite side of the rotor 12 on the substrate body 32, that is, the upper surface 32A. In the exemplary embodiment shown in the figure, the plane P is orthogonal to the axial direction X. A through hole 34 is formed in the substrate body 32 that penetrates in the axial direction X. Hereinafter, the surface on the opposite side of the rotor 12 on the substrate body 32 is recorded as the "upper surface 32A" of the substrate body 32, and the surface on the rotor 12 side of the substrate body 32 is recorded as the "lower surface 32B" of the substrate body 32.

[0085] The substrate body 32 is a so-called printed substrate, which is a printed circuit board (PCB) formed by assembling various electronic components on a printed wiring board (PWB) such as a glass epoxy resin substrate, wherein the glass epoxy resin substrate is formed by fiber-reinforced resin, which is obtained by hardening a cloth woven from, for example, glass fiber, using epoxy resin. In addition, the printed wiring board may be, for example, a composite substrate mixed with paper and a glass substrate, a flexible substrate, or a ceramic substrate.

[0086] The through hole 34 is formed from the lower surface 32B to the upper surface 32A of the substrate body 32 , and the cross-sectional shape of the through hole 34 perpendicular to the axial direction X is formed in a circular shape, for example.

[0087] The terminal 40 is a conductive member formed of a metal such as copper, and electrically connects the electronic substrate 30 and the coil 18 by connecting to the coil wire 20. The coil wire 20 of the coil 18 is inserted through the through hole 34 and welded to the terminal 40 by fusion on the opposite side of the rotor 12 via the substrate body 32.

[0088] Here, the vehicle-mounted electric oil pump using the vehicle-mounted brushless motor device 1 is sometimes arranged next to the transmission shaft or the like in the axial direction X. Therefore, if the vehicle-mounted brushless motor device 1 can be miniaturized in the axial direction X, interference with movable parts such as the transmission shaft can be avoided, thereby improving the degree of freedom in design.

[0089] In this regard, according to the structure of the present disclosure described above, since the coil wire 20 of the coil 18 is directly welded to the terminal 40 on the opposite side of the rotor 12 via the substrate body 32, the distance between the electronic substrate 30 and the winding portion of the coil 18 can be shortened compared to the case where the coil is connected to the electronic substrate via a hard terminal pin or the like disposed between the electronic substrate and the coil, thereby providing a vehicle-mounted brushless motor device 1 that can be miniaturized in the axial direction X. In addition, compared to the case where the coil is connected to the electronic substrate via a terminal pin, the number of welding positions can be reduced, thereby providing a vehicle-mounted brushless motor device 1 with improved assemblability.

[0090] In some embodiments, for example, Figure 1 and Figure 2A As shown, the above-mentioned vehicle-mounted brushless motor device 1 can also have a retainer unit 50, which includes: a connector terminal 58, which is used to connect the electronic substrate 30 to an external device not shown; and a retainer 52, which is arranged between the substrate body 32 and the brushless motor 10 and supports the electronic substrate 30.

[0091] The holder 52 functions as a partition member that partitions the space where the brushless motor 10 is arranged and the space where the electronic substrate 30 is arranged, and functions as a support portion that rotatably supports the output shaft 14 of the brushless motor 10 via a bearing (not shown). The holder 52 is made of resin and can be formed by, for example, insert molding. Figure 1 As shown, the retainer 52 includes a groove 51 formed along the outer periphery of the retainer 52 on the peripheral portion of the upper surface side thereof. By filling the groove 51 with adhesive, the airtightness between the space where the electronic substrate 30 is arranged and the outside of the vehicle-mounted brushless motor device 1 can be ensured.

[0092] The connector terminal 58 is formed integrally with the holder 52 by burying a part of the connector terminal 58 in the holder 52. For example, the holder unit 50 is formed by insert molding the holder 52 in a state where a part of the connector terminal 58 is buried inside. One end 58A of the connector terminal 58 is set to protrude upward from the upper surface of the holder 52, and is connected to the electronic substrate 30 arranged above by, for example, soldering. The other end 58B of the connector terminal 58 is set in a state protruding from the peripheral portion of the holder 52 toward, for example, a horizontal direction. The connector terminal 58 is a conductive component formed of a metal such as copper, and its other end 58B electrically connects the electronic substrate 30 to the external device by connecting to an external device not shown. In addition, the other end 58B of the connector terminal 58 can be set in a manner protruding upward or downward from the peripheral portion of the holder 52, for example, according to the relative configuration with the external device to be connected.

[0093] The third soldering portion 63 can be configured to, for example, connect one end 58A of the connector terminal 58 to a metal foil terminal portion 85, wherein the one end 58A of the connector terminal 58 is configured to protrude upward from the upper surface 32A of the substrate body 32 through a through hole 35 that penetrates the substrate body 32 in the axial direction X, and the metal foil terminal portion 85 is disposed on the upper surface 32A of the substrate body 32.

[0094] According to the vehicle-mounted brushless motor device 1, by providing the holder unit 50 in which the holder 52 and the connector terminal 58 are integrally formed between the electronic substrate 30 and the brushless motor 10, it is possible to provide a vehicle-mounted brushless motor device 1 that supports the electronic substrate 30 disposed on the opposite side of the rotor 12 via the holder unit 50 by the holder 52, and that can easily connect the electronic substrate 30 to an external device and is easy to assemble. In addition, by using a structure in which the connector terminal 58 is connected to the metal foil terminal portion 70 via the third soldering portion 63, soldering can be performed from above the substrate body 32, so that a vehicle-mounted brushless motor device 1 with improved assemblability can be provided.

[0095] In some embodiments, for example, Figure 1 and Figure 2A As shown, in the structure including the above-mentioned holder unit 50 , the holder 52 may include a guide hole 54 that penetrates the holder 52 in the axial direction X and is used to guide the coil wire 20 from the brushless motor 10 side to the through hole 34 of the substrate body 32 .

[0096] The guide hole 54 is formed to penetrate the holder 52 from the lower surface side to the upper surface side of the holder 52 in the axial direction X, and the cross-sectional shape of the guide hole 54 perpendicular to the axial direction X is formed into, for example, a circle. In addition, the guide hole 54 is formed so that the opening end of the guide hole 54 on the electronic substrate 30 side (upper side), that is, the substrate side opening end 56, overlaps with the through hole 34 when viewed in the axial direction X (more specifically, the substrate side opening end 56 is accommodated inside the through hole 34 when viewed in the axial direction X).

[0097] According to the vehicle-mounted brushless motor device 1, the holder 52 includes the guide hole 54, so that the coil wire 20 can be guided from the brushless motor 10 side (lower side) of the holder 52 toward the upper side, and the coil wire 20 can be guided to the through hole 34 of the electronic substrate 30. Therefore, one end of the coil wire 20, which is relatively soft and has an uncertain shape compared to a hard component such as a terminal pin, can be smoothly guided to the through hole 34 of the electronic substrate 30, so that the vehicle-mounted brushless motor device 1 with improved assemblability can be provided. In addition, by removing the insulating film of the coil wire 20 of the coil 18 in advance, soldering is facilitated.

[0098] Figure 3 to Figure 5 1 is a diagram showing a configuration example of a terminal 40 according to an embodiment. Figure 3 is a top view (axial X view) of terminal 40, Figure 4 is a side view of terminal 40, Figure 5 is a bottom view (axial X view) of the terminal 40. In addition, Figure 3 to Figure 5 The terminal 40 is shown in a state before the terminal 40 and the coil wire 20 are fusion-welded.

[0099] In some embodiments, for example, Figure 3 to Figure 5 As shown, in the above structure, a first slit 41 extending along a first direction a1 included in the plane P may be formed on the terminal 40. The terminal 40 includes: a first terminal portion 43, which is provided on one side across the first slit 41; a second terminal portion 44, which is provided on the other side across the first slit 41; a third terminal portion 45, which connects the first terminal portion 43 and the second terminal portion 44; and a protrusion 80, which is provided to protrude from the second terminal portion 44 to the opposite side of the rotor 12 in the axial direction.

[0100] The first terminal portion 43, the second terminal portion 44, and the third terminal portion 45 are integrally formed on a flat plate to form a base portion 42 of the terminal 40. The base portion 42 may be a flat plate-shaped member that is, for example, J-shaped, U-shaped, or V-shaped when viewed in the axial direction X, and is disposed opposite to the upper surface 32A of the substrate body 32 and parallel to the plane P.

[0101] The protrusion 80 is welded to the coil wire 20, and the first terminal 43 is connected to the substrate body 32 via the first soldering portion 90. In this specification, a "soldering portion" refers to solder located between multiple (eg, two) components when the components are connected by soldering.

[0102] It is known that the melting point of typical lead-free solder is, for example, about 218 degrees Celsius. On the other hand, in fusion soldering, for example, in which copper is melted, a temperature of about 1000 degrees Celsius or more, which is the melting point of copper, is generated, and the soldered portion melts again due to the heat, and the terminal may fall off the electronic substrate.

[0103] In contrast, according to the brushless motor device 1, the size of the terminal 40 can be suppressed and the distance from the protruding portion 80 to the first soldering portion 90 along the surface of the terminal 40 (along the Figure 3 Therefore, it is possible to prevent the heat of welding from being transferred from the protruding portion 80 to the first soldering portion 90 when the protruding portion 80 and the coil wire 20 are fused and welded, thereby preventing the first soldering portion 90 from melting again. Therefore, it is possible to prevent the brushless motor device 1 from being enlarged, and to achieve a good electrical connection state between the electronic substrate 30 and the coil 18.

[0104] In some embodiments, for example, Figure 5 As shown, the second terminal portion 44 includes a second soldering portion 92 soldered to the substrate body 32, and the first soldering portion 90 is separated from the second soldering portion 92. The first soldering portion 90 and the second soldering portion 92 are arranged to extend parallel to each other with the first slit 41 interposed therebetween.

[0105] According to this structure, the coil 18 can be electrically connected to the electronic substrate 30 via the first soldering portion 90 and the second soldering portion 92. Furthermore, since the first soldering portion 90 and the second soldering portion 92 are separated, even if the second soldering portion 92 is melted again due to the heat of welding the protruding portion 80 and the coil wire 20, the first soldering portion 90 can be suppressed from melting again. Thus, a good electrical connection state between the electronic substrate 30 and the coil 18 can be achieved.

[0106] In some embodiments, for example, Figure 3 to Figure 5 As shown, the third terminal portion 45 is connected to one end 44a of the second terminal portion 44 in the first direction a1, and the protrusion 80 is connected to the other end 44b of the second terminal portion 44 in the first direction a1.

[0107] According to this structure, the distance from the protruding portion 80 to the third terminal portion 45 along the surface of the terminal 40 can be increased. Therefore, it is possible to suppress the enlargement of the shape of the terminal 40, and to increase the distance from the protruding portion 80 to the first soldering portion 90 along the surface of the terminal 40. Therefore, it is possible to effectively suppress the heat of welding from the protruding portion 80 to the first soldering portion 90 when the protruding portion 80 and the coil wire 20 are fusion-welded, thereby suppressing the first soldering portion 90 from melting again.

[0108] In some embodiments, for example, Figure 3 and Figure 4 As shown, the protrusion 80 includes a base end portion 80a connected to the other end portion 44b of the second terminal portion 44, and a hook portion 80b formed in a hook shape and engaged with the coil wire 20. In the illustrated exemplary embodiment, the base end portion 80a is formed in a flat plate shape along a plane intersecting with the arrow a1 (a plane orthogonal to the arrow a1 in the illustrated embodiment), and the hook portion 80b is formed in a plate shape extending from the base end portion 80a and being bent or zigzag. The hook portion 80b can be bent so that the front end is folded back toward the second terminal portion 44 side to surround the coil wire 20 protruding from the upper surface 32A of the substrate body 32. In addition, with respect to the terminal 40 configured as described above, the base portion 42 and the protrusion 80 can be formed as a whole using the same component.

[0109] According to the vehicle-mounted brushless motor device 1 having this structure, it is possible to ensure that the distance from the hook portion 80b arranged at the front end of the protrusion 80 and fusion-welded with the coil wire 20 through the base end portion 80a of the protrusion 80, the second terminal portion 44 and the third terminal portion 45 to the first terminal portion 43 is long, thereby preventing the heat generated when the hook portion 80b is welded to the coil wire 20 from being transferred to the first soldering portion 90.

[0110] Figure 6 It is schematically indicated Figure 3 A plan view of a structural example of a terminal 40 is shown.

[0111] In some embodiments, for example, Figure 6 As shown, in the structure where the terminal 40 includes the first terminal portion 43 and the second terminal portion 44 , the length L2 of the second terminal portion 44 in the first direction a1 may be longer than the length L1 of the first terminal portion 43 in the first direction a1 .

[0112] According to the vehicle-mounted brushless motor device 1 having this structure, the distance from the protrusion 80 to the first soldering portion 90 along the surface of the terminal 40 can be increased, so that the first soldering portion 90 can be prevented from being melted again by the heat of welding the protrusion 80 and the coil wire 20 .

[0113] Figure 7 It is a perspective view schematically showing the metal foil terminal portion 70 according to one embodiment. Figure 8 It is a perspective view schematically showing the first opening 76 and the second opening 78 of the protective layer 75 according to one embodiment. Fig. 9 It is a perspective view schematically showing a state where the terminal 40 according to one embodiment is mounted on the substrate body 32 . Fig.10 It is a plan view schematically showing a configuration example of the metal foil terminal portion 70 according to one embodiment.

[0114] In some embodiments, in the structure including the first soldering portion 90 and the second soldering portion 92, for example Figure 7 to Figure 10 As shown, the electronic substrate 30 may include a metal foil terminal portion 70 and a protective layer 75, wherein the metal foil terminal portion 70 is adjacent to the through hole 34 and is arranged along the surface on the opposite side of the rotor 12 on the substrate body 32, that is, the upper surface 32A, and the protective layer 75 is arranged on the metal foil terminal portion 70 and has a first opening portion 76 corresponding to the first soldering portion 90 and a second opening portion 78 corresponding to the second soldering portion 92.

[0115] For example Figure 7 As shown, a second slit 73 extending along the first direction a1 is formed on the metal foil terminal portion 70. That is, the slit 41 and the slit 73 extend in the same direction. The metal foil terminal portion 70 includes a first portion 71, a second portion 72, and a third portion 74. Figure 7 and Figure 8 As shown, the first portion 71 is disposed on one side with the second slit 73 opened at one end interposed therebetween, and is connected to the first soldering portion 90 (see Figure 5 ). Thus, the first portion 71 is connected to the first terminal portion 43 via the first soldering portion 90 located in the first opening 76. The second portion 72 is provided on the other side across the second slit 73 and is connected to the second soldering portion 92 (see Figure 5 Thus, the second portion 72 is connected to the second terminal portion 44 via the second soldering portion 92 located in the second opening portion 78 .

[0116] The metal foil terminal portion 70 may be a flat plate-shaped member having, for example, a J-shape, a U-shape, or a V-shape when viewed in the axial direction X, and is disposed parallel to the plane P facing the upper surface 32A of the substrate body 32 .

[0117] The second portion 72 functions as a heat sink for dissipating heat generated when the hook portion 80b is welded to the coil wire 20. The first portion 71 and the second portion 72 may be arranged to extend parallel to each other with the second slit 73 interposed therebetween.

[0118] According to the vehicle-mounted brushless motor device 1 having such a structure, in the transfer path of heat generated by welding the hook portion 80b and the coil wire 20, most of the heat can be dissipated in the second portion 72 at a position closer to the front than the first soldering portion 90. Therefore, even if the second soldering portion 92 is melted again due to the heat generated in welding the hook portion 80b and the coil wire 20, the electronic substrate 30 (more specifically, the metal foil terminal portion 70) and the coil 18 can be electrically connected to each other at least via the first soldering portion 90, so that a good electrical connection state between the electronic substrate 30 and the coil 18 can be achieved.

[0119] In some embodiments, for example, Fig.10 As shown, the area A2 of the second portion 72 may be larger than the area A1 of the first portion 71. In this case, the area A2 of the second portion 72 may be 1.2 times or more of the area A1 of the first portion 71. In addition, more preferably, the area A2 of the second portion 72 may be 1.4 times or more of the area A1 of the first portion 71.

[0120] According to the vehicle-mounted brushless motor device 1 of this structure, in the transfer path of heat generated by welding the hook portion 80b and the coil wire 20, most of the heat can be dissipated in the second portion 72 having an area L2 larger than the first portion 71 or having an area L2 that is 1.2 times or more of the first portion 71, which is closer to the front than the first terminal portion 43 or the first soldering portion 90. Therefore, even if the second soldering portion 92 is melted again due to the heat of welding the protruding portion 80 and the coil wire 20, the first soldering portion 90 can be suppressed from melting again. Therefore, since the electronic substrate 30 (more specifically, the metal foil terminal portion 70) and the coil 18 can be more reliably connected via at least the first soldering portion 90, the yield rate of the vehicle-mounted brushless motor device 1 can be effectively suppressed from being reduced.

[0121] In some embodiments, for example, Fig. 9 As shown, in any of the above-mentioned structures, the electronic substrate 30 may include a plurality of terminals 40 , and each of the plurality of terminals 40 may be configured to be oriented in the same direction with respect to the substrate body 32 .

[0122] Specifically, the electronic board 30 may be configured such that the orientations of the first terminal portion 43 , the second terminal portion 44 , the protrusion 80 , or the hook portion 80 b relative to the board body 32 are uniform in each terminal 40 .

[0123] According to the vehicle-mounted brushless motor device 1 of this structure, each terminal 40 can be automatically assembled on the substrate body 32 using, for example, a mounter device (automatic assembly device) not shown in the figure, and there is no need to change the orientation of the mounter device or the substrate body 32 when assembling each terminal 40, so that a vehicle-mounted brushless motor can be provided that can shorten the time required for assembly and improve assemblability. In addition, the vehicle-mounted brushless motor device 1 can be assembled at a low cost.

[0124] Fig.11 It is a plan view schematically showing the upper region of the electronic substrate 30 according to one embodiment. Fig.12 It is a side view schematically showing the upper region of the electronic substrate 30 according to one embodiment.

[0125] According to the above-mentioned vehicle-mounted brushless motor device 1 disclosed in the present invention, for example Fig.11 and Fig.12 As shown, a tool area 84 for welding device electrodes is provided above the electronic substrate 30 for welding. Therefore, interference between components arranged around the terminal 40 and the welding device electrodes can be suppressed, and the assemblability of the vehicle-mounted brushless motor device 1 can be improved.

[0126] Fig.13 It is a side cross-sectional view showing a structural example of the guide hole 54 in one embodiment. Fig.14 It is a side cross-sectional view showing a modified example of the guide hole 54 in one embodiment.

[0127] In some embodiments, for example, Figure 2A , Fig.13 and Fig.14 As shown, in the vehicle-mounted brushless motor device 1 in which the retainer 52 includes the guide hole 54, the guide hole 54 may include a tapered channel portion 57 formed in a tapered shape in which the hole diameter (channel diameter) decreases as it moves away from the rotor 12 in the axial direction X.

[0128] Thus, one end of the coil wire 20 can be smoothly guided to the through hole 34 via the tapered channel portion 57 of the electronic substrate 30, thereby providing a vehicle-mounted brushless motor device 1 with improved assemblability. For example, the retainer unit 50 and the coil 18 to which the electronic substrate 30 is pre-assembled can be assembled using an automatic assembly device. Thereafter, the electronic substrate 30 and the coil 18 can be electrically connected by fusion welding the hook portion 80 b and the coil wire 20.

[0129] The opening end of the guide hole 54 on the brushless motor 10 side, that is, the motor side opening end 55, has a diameter sufficiently larger than the diameter of the coil wire 20. Specifically, for example, Fig.13 and Fig.14As shown, when the diameter of the coil wire 20 is set to d1 and the diameter of the motor side opening end 55 (the inner diameter of the motor side opening end 55) is set to d2, the motor side opening end 55 can be configured to satisfy, for example, 3≤d2 / d1. In addition, the "diameter of the motor side opening end 55" represents the hole diameter (channel diameter) of the guide hole 54 at the position of the motor side opening end 55.

[0130] In some embodiments, for example, Fig.13 as well as Fig.14 As shown, the guide hole 54 may include a substrate-side channel portion 60 having a constant channel diameter in the axial direction. In the illustrated embodiment, the substrate-side channel portion 60 is configured to connect the substrate-side opening end 56 and the upper end of the tapered channel portion 57 .

[0131] Thus, when the coil wire 20 guided to the guide hole 54 passes through the substrate-side channel portion 60, since the coil wire 20 can be oriented upward, the coil wire 20 can be guided toward the through hole 34 of the electronic substrate 30 more easily and smoothly. In addition, in other embodiments, regarding the guide hole 54, the tapered channel portion 57 may be formed from, for example, the motor-side opening end 55 to the substrate-side opening end 56. That is, the lower end of the tapered channel portion 57 may be the motor-side opening end 55, and the upper end of the tapered channel portion 57 may be the substrate-side opening end 56.

[0132] In some embodiments, for example, Fig.13 as well as Fig.14 As shown, the retainer 52 may include a cylindrical portion 82 that protrudes toward the opposite side of the rotor 12 .

[0133] In this case, at least a portion of the guide hole 54 is formed by the inner peripheral surface 82A of the cylindrical portion 82. In this case, the upper end of the inner peripheral surface 82A of the cylindrical portion 82, that is, the substrate-side opening end 56 may be formed as shown in FIG. Fig.13 As shown in the figure, it can be arranged below the through hole 34, or it can be arranged inside the through hole 34, or it can be arranged as shown in the figure. Fig.14 The configuration shown is flush with the upper surface 32A of the electronic substrate 30, and can also be configured to be closer to the upper side than the upper surface 32A of the electronic substrate 30. Fig.14 As shown, at least a portion of a cylindrical substrate-side portion 82B in which the substrate-side channel portion 60 is formed on the inner peripheral surface of the cylindrical portion 82 may be disposed inside the through hole 34 .

[0134] like Fig.14 As shown, by arranging the substrate-side portion 82B of the cylindrical portion 82 inside the through hole 34 , one end of the coil wire 20 can be smoothly guided through the through hole 34 of the electronic substrate 30 , thereby providing a vehicle-mounted brushless motor device 1 with improved assemblability.

[0135] In some embodiments, for example, Fig.13 and Fig.14 As shown in FIG. 1 , in the vehicle-mounted brushless motor device 1 in which the guide hole 54 includes the tapered channel portion 57, the diameter D2 of the substrate-side opening end 56 (the inner diameter of the substrate-side opening end 56) can be smaller than the diameter D1 of the through hole 34. According to the vehicle-mounted brushless motor device 1 of this structure, the coil wire 20 passing through the substrate-side opening end 56 can be guided to the through hole 34 of the electronic substrate 30 more easily and smoothly. In addition, the "diameter of the substrate-side opening end 56" means the hole diameter (channel diameter) of the guide hole 54 at the position of the substrate-side opening end 56.

[0136] Next, a method for manufacturing the vehicle-mounted brushless motor device according to one embodiment of the present disclosure will be described. Fig.15 FIG. 1 is a flow chart showing a method for manufacturing a vehicle-mounted brushless motor device according to an embodiment of the present invention. Fig.15 As shown, the manufacturing method of the vehicle-mounted brushless motor device 1 includes: step S1, arranging the substrate body 32 of the electronic substrate 30 on the opposite side of the output side of the brushless motor 10 along the plane P intersecting the axial direction X; step S2, passing the coil wire 20 of the coil 18 constituting the stator 16 of the brushless motor 10 through the through hole 34 of the electronic substrate 30; and step S3, welding the coil wire 20 to the hook portion 80b of the terminal 40 on the opposite side of the rotor 12 through the electronic substrate 30, and the terminal 40 is fixed on the surface on the opposite side of the rotor 12 on the substrate body 32, that is, the upper surface 32A.

[0137] In step S1, the electronic substrate 30 equipped with various electronic components for controlling the drive of the brushless motor 10 is arranged on the upper surface of the holder unit 50 that separates, for example, the space where the brushless motor 10 is arranged and the space where the electronic substrate 30 is arranged. At this time, the electronic substrate 30 can be arranged so that, for example, the through hole 34 and the guide hole 54 overlap when viewed in the axial direction X, wherein the through hole 34 is a through hole pre-formed in the electronic substrate 30 for inserting the coil wire 20, and the guide hole 54 is a guide hole pre-formed in the holder unit 50 for guiding the coil wire 20 to the through hole 34. In addition, the third soldering portion 63 that connects the one end 58A of the connector terminal 58 to the metal foil terminal portion 85 is formed.

[0138] Furthermore, as a pre-process of step S1, a metal foil terminal portion 70 is provided on the substrate body 32, a protective layer 75 is arranged on the metal foil terminal portion 70, and the first portion 71 exposed to the inner side of the first opening portion 76 is connected to the first terminal portion 43 by soldering to form a first soldering portion 90. In addition, the second portion 72 exposed to the inner side of the second opening portion 78 is connected to the second terminal portion 44 by soldering to form a second soldering portion 92.

[0139] In step S2, one end of the coil wire 20 is passed through the through hole 34 by guiding the coil wire 20 along the tapered channel portion 57 as, for example, a guide hole 54, wherein the tapered channel portion 57 is pre-formed in the retainer 52 of the retainer unit 50 in a manner such that the diameter decreases from the lower surface side of the retainer 52 toward the upper surface side.

[0140] In step S3, for example, one end of the coil wire 20 protruding toward the upper side of the electronic substrate 30 through the through hole 34 is arranged so that the end faces upward, and the coil wire 20 and the terminal 40 are fusion-welded so that the coil wire 20 is arranged inside the hook portion 80b. In addition, the metal foil terminal portion 70 is provided on the substrate body 32, and the protective layer 75 is provided on the metal foil terminal portion 70, and the first soldering portion 90 is soldered to the first portion 71 exposed to the inner side of the first opening portion 76, and the second soldering portion 92 is soldered to the second portion 72 exposed to the inner side of the second opening portion 78.

[0141] According to the manufacturing method of the vehicle-mounted brushless motor device 1, as described above, the coil wire 20 of the coil 18 is directly fused and welded to the terminal 40 on the opposite side of the rotor 12 through the through hole 34 of the substrate body 32, so that it is possible to provide a vehicle-mounted brushless motor device 1 that can be miniaturized in the axial direction X compared to the case where the coil 18 is connected to the electronic substrate 30 via a hard member such as a terminal pin. In addition, compared to the case where the coil 18 is connected to the electronic substrate 30 via a terminal pin, the number of welding positions can be reduced, so the vehicle-mounted brushless motor device 1 can be easily manufactured.

[0142] According to at least one embodiment of the present disclosure, it is possible to provide a vehicle-mounted brushless motor device that can be miniaturized in the axial direction of a rotor and a method for manufacturing the same.

[0143] The present invention is not limited to the above-described embodiment, and includes forms in which the above-described embodiment is modified and forms in which these forms are combined.

[0144] For example, in some of the above-mentioned embodiments, an electric oil pump 1A (oil supply device) equipped with a brushless motor 10 is used as an example for description as a vehicle-mounted brushless motor device 1, but the vehicle-mounted brushless motor device 1 disclosed in the present invention is not limited to this, and can also be applied to, for example, an electronically controlled variable valve timing system (Variable Valve Timing system: VVT), an electric water pump (Electric Water Pump: EWP), a parking lock actuator (Parking Lock Actuator: PLA), etc. equipped with a brushless motor 10.

Claims

1. A vehicle-mounted brushless motor device, comprising a brushless motor and an electronic substrate, wherein: The brushless motor includes a rotor and a stator including a plurality of coils arranged around the rotor. The electronic substrate comprises: a substrate body having a through hole formed therein and penetrating in the axial direction of the rotor and arranged on the opposite side of the output side of the brushless motor along a plane intersecting the axial direction; and a terminal fixed to a surface of the substrate body on the opposite side of the rotor, The coil wire of the coil is inserted into the through hole and is welded to the terminal on the opposite side of the rotor via the substrate body. A first slit extending along a first direction included in the plane is formed on the terminal, The terminal comprises: A first terminal portion, which is arranged on one side across the first slit; a second terminal portion, which is disposed on the other side across the first slit; a third terminal portion connecting the first terminal portion and the second terminal portion; and a protrusion provided to protrude from the second terminal portion toward the opposite side of the rotor in the axial direction, The protrusion is welded to the coil wire, The first terminal portion is connected to the substrate body via a first soldering portion.

2. The vehicle-mounted brushless motor device according to claim 1, characterized in that: The second terminal portion is connected to the substrate body via a second soldering portion. The first soldering portion is separated from the second soldering portion.

3. The vehicle-mounted brushless motor device according to claim 1 or 2, characterized in that: The third terminal portion is connected to one end of the second terminal portion in the first direction, The protruding portion is connected to the other end portion of the second terminal portion in the first direction.

4. The vehicle-mounted brushless motor device according to claim 1 or 2, characterized in that: The protrusion includes a hook portion that is formed in a hook shape and is welded to the coil wire by fusion.

5. The vehicle-mounted brushless motor device according to claim 1 or 2, characterized in that: The length of the second terminal portion in the first direction is longer than the length of the first terminal portion in the first direction.

6. The vehicle-mounted brushless motor device according to claim 2, wherein: The electronic substrate comprises: a metal foil terminal portion adjacent to the through hole and arranged along a surface of the substrate body on the opposite side to the rotor; and a protective layer disposed on the metal foil terminal portion and having a first opening corresponding to the first soldering portion and a second opening corresponding to the second soldering portion, A second slit extending in the first direction is formed on the metal foil terminal portion, The metal foil terminal portion comprises: A first portion, which is disposed on one side across the second slit and connected to the first soldering portion at the first opening; a second portion disposed on the other side across the second slit and connected to the second soldering portion at the second opening; and A third portion connects the first portion and the second portion.

7. The vehicle-mounted brushless motor device according to claim 6, characterized in that: An area of ​​the second portion is larger than an area of ​​the first portion.

8. The vehicle-mounted brushless motor device according to claim 7, characterized in that: The area of ​​the second portion is greater than or equal to 1.2 times the area of ​​the first portion.

9. The vehicle-mounted brushless motor device according to any one of claims 1 or 2, characterized in that: The electronic substrate comprises a plurality of the terminals. Each of the plurality of terminals is oriented in the same direction relative to the substrate body.

10. The vehicle-mounted brushless motor device according to any one of claims 1 or 2, characterized in that: The vehicle-mounted brushless motor device further includes a retainer unit, the retainer unit including: a connector terminal for connecting the electronic substrate to an external device; and a holder, which is arranged between the substrate body and the brushless motor and supports the electronic substrate, The electronic substrate includes a third soldering portion for connecting to the connector terminal.

11. The vehicle-mounted brushless motor device according to claim 10, characterized in that: The holder includes a guide hole that penetrates the holder in the axial direction and guides the coil wire from the brushless motor side to the through hole of the substrate body.

12. The vehicle-mounted brushless motor device according to claim 11, characterized in that: The guide hole includes a tapered passage portion formed such that a hole diameter becomes smaller as it becomes farther away from the rotor in the axial direction.

13. The vehicle-mounted brushless motor device according to claim 11, characterized in that: The diameter of the opening end of the guide hole on the electronic substrate side is smaller than the diameter of the through hole.

14. A method for manufacturing a brushless motor device for a vehicle, comprising the following steps: Arrange a substrate body of the electronic substrate on the opposite side of the output side of the brushless motor along a plane intersecting the axial direction of the rotor of the brushless motor; Passing a coil wire of a coil constituting a stator of the brushless motor through the through hole of the electronic substrate; as well as The coil wire is welded to a terminal on the opposite side of the rotor via the electronic substrate, and the terminal is fixed to a surface on the opposite side of the rotor on the substrate body. A first slit extending along a first direction included in the plane is formed on the terminal, The terminal comprises: A first terminal portion, which is arranged on one side across the first slit; a second terminal portion, which is disposed on the other side across the first slit; a third terminal portion connecting the first terminal portion and the second terminal portion; as well as a protrusion provided to protrude from the second terminal portion toward the opposite side of the rotor in the axial direction, In the step of welding the coil wire, the protruding portion of the terminal is welded to the coil wire, The first terminal portion is connected to the substrate body via a first soldering portion.

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