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). 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) is arranged on the opposite side of the output side of the brushless motor (10) along a plane (P) intersecting the axial direction (X). The brushless motor device (1) also includes a soldering portion (40) that connects a coil wire (20) of the coil (18) to the electronic substrate (30).

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) At least one embodiment of the present invention comprises a brushless motor device for use in a vehicle, wherein the brushless motor includes a rotor and a stator including a plurality of coils arranged around the rotor, the electronic substrate is arranged on the opposite side of the output side of the brushless motor along a plane intersecting the axial direction of the rotor, and the electronic substrate further comprises a soldering portion connecting the coil wire of the coil to the electronic substrate.

[0011] (2) In some embodiments, the vehicle-mounted brushless motor device described in (1) above may also include a retainer unit, wherein the retainer unit includes: a connector terminal for connecting the electronic substrate with an external device; and a retainer that is arranged between the electronic substrate and the brushless motor and supports the electronic substrate.

[0012] (3) In some embodiments, in the vehicle-mounted brushless motor device described in (2) above, the electronic substrate may include a through hole that penetrates the electronic substrate axially, and the retainer may include a guide hole for guiding the coil wire from the brushless motor side to the through hole of the electronic substrate.

[0013] (4) In some embodiments, in the vehicle-mounted brushless motor device described in (3) above, the guide hole may include a tapered channel portion, and the tapered channel portion may be formed so that the hole diameter decreases as it moves away from the rotor in the axial direction.

[0014] (5) In some embodiments, in the vehicle-mounted brushless motor device described in (4) above, the guide hole may include a substrate-side channel portion, the substrate-side channel portion connects the open end of the electronic substrate side on the guide hole with the tapered channel portion, and the channel diameter of the substrate-side channel portion is constant in the axial direction.

[0015] (6) In some embodiments, in the vehicle-mounted brushless motor device described in any one of (3) to (5) 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.

[0016] (7) In some embodiments, in the vehicle-mounted brushless motor device described in any one of (3) to (6) above, the soldering portion may connect the coil wire to the inner circumferential surface of the through hole, and the coil wire may be configured to protrude from the through hole toward the opposite side of the rotor on the electronic substrate.

[0017] (8) In some embodiments, in the vehicle-mounted brushless motor device described in any one of (3) to (6) above, the electronic substrate may include a metal foil terminal portion arranged adjacent to the through hole, the soldering portion connects the coil wire to the metal foil terminal portion, and the coil wire passes through the through hole and is arranged along the metal foil terminal portion.

[0018] (9) In some embodiments, in the vehicle-mounted brushless motor device described in any one of (3) to (6) above, the electronic substrate may include: a metal foil terminal portion, which is arranged on a surface on the electronic substrate opposite to the rotor; and a protective layer, which is arranged on the metal foil terminal portion and has a first opening portion and a second opening portion, wherein the first opening portion allows the coil wire to pass through axially, the second opening portion is separated from the first opening portion and exposes at least a portion of the metal foil terminal portion, and the soldering portion is arranged to connect the metal foil terminal portion to the coil wire via the second opening portion.

[0019] (10) A method for manufacturing a vehicle-mounted brushless motor device according to at least one embodiment of the present invention comprises the following steps: arranging an electronic substrate on the opposite side of an output side of the brushless motor along a plane intersecting the axial direction of a rotor of the brushless motor; passing a coil wire of a coil constituting a stator of the brushless motor through a through hole of the electronic substrate; and soldering the coil wire protruding from the through hole to the electronic substrate.

[0020] (III) Beneficial effects

[0021] 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

[0022] 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.

[0023] Figure 2A It means in Figure 1 A partial enlarged view of region II indicated by a dotted line.

[0024] Figure 2B This is a diagram showing an example of the arrangement of magnets.

[0025] Figure 3 It is a side cross-sectional view showing a structural example of a guide hole in one embodiment.

[0026] Figure 4 It is a side cross-sectional view showing a modified example of the guide hole in one embodiment.

[0027] Figure 5 It is a perspective view illustrating the shape of a soldering portion in one embodiment.

[0028] Figure 6 It is a perspective view schematically showing a modified example of the soldering portion in one embodiment.

[0029] Figure 7 It is a perspective view schematically showing a modified example of the soldering portion in one embodiment.

[0030] Figure 8 This is a flowchart showing a method for manufacturing a vehicle-mounted brushless motor device according to one embodiment.

[0031] Description of Reference Numerals

[0032] 1-a vehicle-mounted brushless motor device; 10-a brushless motor; 12-a rotor; 16-a stator; 18-a coil; 20-a coil wire; 30-an electronic substrate; 34-a through hole; 36-an inner circumference; 40-a soldering portion; 42-a metal foil terminal portion; 44-a protective layer; 46-a first opening portion; 48-a second opening portion; 50-a retainer unit; 52-a retainer; 54-a guide hole; 55-an opening end on the motor side; 56-an opening end on the substrate side; 57-a tapered channel portion; 58-a connector terminal; 60-a channel portion on the substrate side; P-a plane; X-axial direction. DETAILED DESCRIPTION

[0033] 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, but are merely illustrative examples.

[0034] 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.

[0035] 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.

[0036] 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.

[0037] 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.

[0038] 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.

[0039] like Figure 1 and Figure 2AAs 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 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 for controlling the drive of the brushless motor 10.

[0040] 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 .

[0041] The rotor 12 is arranged inside the stator 16, and is composed of an output shaft 14 (rotation 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 into multiple poles (for example, six poles). Figure 2B ).exist Figure 2B In the illustrated embodiment, the plate-shaped S-pole magnet portion 15a and the plate-shaped N-pole magnet portion 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 can rotate together with the output shaft 14.

[0042] 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 in the axial direction X (the direction from the opposite side of the output side of the brushless motor 10 toward the output side of the brushless motor 10) is described as “downward” or simply “downward”, and the direction from the brushless motor 10 toward the electronic substrate 30 in the axial direction X (the direction from the output side of the brushless motor 10 toward the opposite side of the output side of the brushless motor 10) is described as “upward” or simply “upward”.

[0043] The stator 16 includes a housing (motor housing) 4 which also serves as a yoke, a plurality of stator cores (core components) 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.

[0044] The electronic substrate 30 is arranged on the opposite side of the output side of the brushless motor 10 along a plane P intersecting the axial direction X. In the exemplary embodiment shown in the figure, the plane P is orthogonal to the axial direction X. The electronic substrate 30 is a so-called printed substrate, which is a printed circuit board (PCB) composed of various electronic components mounted on a printed wiring board (PWB) such as a glass epoxy resin substrate, the glass epoxy resin substrate being formed of a fiber-reinforced resin obtained by hardening a cloth woven from, for example, glass fiber, etc. with epoxy resin. In addition, the printed wiring board may be, for example, a composite substrate in which paper and a glass substrate are mixed, a flexible substrate, or a ceramic substrate.

[0045] The brushless motor device 1 for a vehicle further includes a soldering portion 40 that connects the coil wire 20 of the coil 18 to the electronic substrate 30. That is, the soldering portion 40 electrically connects the end of the coil wire 20 or the vicinity thereof to the electronic substrate 30 on the opposite side to the output side of the brushless motor 10. The soldering portion 40 may be disposed, for example, on the surface of the electronic substrate 30 on the opposite side to the coil 18 and the rotor 12 across the electronic substrate 30 in the axial direction X (that is, on the upper surface 30A of the electronic substrate 30).

[0046] 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.

[0047] In this regard, according to the structure of the present disclosure described above, since the electronic substrate 30 disposed on the opposite side of the output side of the brushless motor 10 is directly connected to the coil wire 20 by the soldering portion 40, 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 member such as a terminal pin, 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 hard terminal member such as a terminal pin, the number of welding positions can be reduced, thereby providing a vehicle-mounted brushless motor device 1 with improved assemblability.

[0048] In some embodiments, for example, Figure 1 and Figure 2A As shown, the above-mentioned vehicle-mounted brushless motor device 1 may further include a holder unit 50, and the holder unit 50 includes: a connector terminal 58 (refer to Figure 1 ), which is used to connect the electronic substrate 30 to an external device not shown; and a holder 52, which is arranged between the electronic substrate 30 and the brushless motor 10 and supports the electronic substrate 30.

[0049] 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.

[0050] 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.

[0051] According to the vehicle-mounted brushless motor device 1, by providing a retainer unit 50 formed by a retainer 52 and a connector terminal 58 between the electronic substrate 30 and the brushless motor 10, it is possible to provide the following vehicle-mounted brushless motor device 1, which uses the retainer 52 to support the electronic substrate 30 arranged on the opposite side of the rotor 12 across the retainer unit 50, and can easily connect the electronic substrate 30 to external equipment and is easy to assemble.

[0052] In some embodiments, for example, Figure 1 and Figure 2A As shown, in the vehicle-mounted brushless motor device 1 having the above-mentioned retainer unit 50, the electronic substrate 30 may include a through hole 34 that penetrates the electronic substrate 30 along the axial direction X, and the retainer 52 may include a guide hole 54 for guiding the coil wire 20 from the brushless motor 10 side to the through hole 34 of the electronic substrate 30.

[0053] The through hole 34 is formed from the lower surface 30B side of the electronic substrate 30 to the upper surface 30A side, and the cross-sectional shape of the through hole 34 perpendicular to the axial direction X is formed into, for example, a circle. The guide hole 54 is formed to penetrate the retainer 52 in the axial direction X from the lower surface side to the upper surface side of the retainer 52, 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).

[0054] According to the vehicle-mounted brushless motor device 1, the holder 52 includes a 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 terminal component such as a terminal pin, can be smoothly guided to the through hole 34 of the electronic substrate 30, so that a vehicle-mounted brushless motor device 1 with improved assemblability can be provided. In addition, as described later, various soldering positions and structures can be adopted, thereby increasing the degree of freedom of the soldering method. In addition, soldering is facilitated by removing the insulating coating of the coil wire 20 of the coil 18 in advance.

[0055] Figure 3 It is a side cross-sectional view showing a structural example of the guide hole 54 in one embodiment. Figure 4 It is a side cross-sectional view showing a modified example of the guide hole 54 in one embodiment.

[0056] In some embodiments, for example, Figure 2A , Figure 3 and Figure 4 As shown, in the above-mentioned vehicle-mounted brushless motor device 1 in which the retainer 52 includes the guide hole 54, the guide hole 54 can include a tapered channel portion 57, which is formed in a tapered shape in such a way that the hole diameter (channel diameter) becomes smaller as it moves away from the rotor 12 in the axial direction X.

[0057] Thus, one end of the coil wire 20 can be smoothly guided to the through hole 34 of the electronic substrate 30 via the tapered channel portion 57, thereby providing a vehicle-mounted brushless motor device 1 with improved assemblability. For example, the holder 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 soldering.

[0058] 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, Figure 3 and Figure 4 As 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 aperture (channel diameter) of the guide hole 54 at the position of the motor side opening end 55.

[0059] In some embodiments, for example, Figure 2A , Figure 3 as well as Figure 4 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 .

[0060] 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.

[0061] In some embodiments, for example, Figure 2A , Figure 3 as well as Figure 4 As shown, the retainer 52 may include a cylindrical portion 70 that protrudes toward the opposite side of the rotor 12 .

[0062] In this case, at least a portion of the guide hole 54 is formed by the inner peripheral surface 70A of the cylindrical portion 70. In this case, the upper end of the inner peripheral surface 70A of the cylindrical portion 70, that is, the substrate-side opening end 56 may be formed as shown in FIG. Figure 2A and Figure 3 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. Figure 4 As shown in FIG. 1 , the electronic substrate 30 may be arranged flush with the upper surface 30A of the electronic substrate 30, or may be arranged above the upper surface 30A of the electronic substrate 30. Figure 4 As shown, at least a portion of a cylindrical substrate-side portion 70B in which the substrate-side channel portion 60 is formed on the inner peripheral surface of the cylindrical portion 70 may be disposed inside the through hole 34 .

[0063] like Figure 4As shown, by arranging the substrate-side portion 70B of the cylindrical portion 70 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.

[0064] In some embodiments, for example, Figure 3 and Figure 4 As shown, 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.

[0065] Figure 5 It is a perspective view illustrating the shape of the soldering portion 40 in one embodiment.

[0066] In some embodiments, such as Figure 3 and Figure 5 As shown, the soldering portion 40 may be provided to connect the coil wire 20 provided to protrude from the through hole 34 to the opposite side of the rotor 12 on the electronic substrate 30 , and the inner peripheral surface 36 of the through hole 34 .

[0067] For example, the soldering portion 40 may be provided to fill a gap between the coil wire 20 and the through hole 34 , wherein the coil wire 20 protrudes toward the upper side of the electronic substrate 30 through the through hole 34 and is arranged with one end facing upward.

[0068] According to the vehicle-mounted brushless motor device 1, it is possible to realize a vehicle-mounted brushless motor device 1 having a structure in which the electronic substrate 30 is arranged on the opposite side of the output side of the brushless motor 10 with a simple structure. In addition, when, for example, the through hole 34 is configured as a through hole, it is possible to obtain a vehicle-mounted brushless motor device 1 in which a metal foil terminal (for example, a copper foil terminal) in the through hole and the coil wire 20 are connected with a simple structure.

[0069] Figure 6 It is a perspective view schematically showing a modified example of the soldering portion 40 in one embodiment.

[0070] In some embodiments, for example, Figure 6 As shown, the electronic substrate 30 may include a metal foil terminal portion 42 disposed adjacent to the through hole 34 , and the soldering portion 40 may be configured to connect the coil wire 20 that passes through the through hole 34 and is disposed along the metal foil terminal portion 42 .

[0071] That is, the soldering portion 40 may be configured to connect the horizontal extension portion 22 with the metal foil terminal portion 42, which is bent in a direction intersecting the axial direction (horizontal direction in the illustrated manner) at one end of the coil wire 20 protruding upward from the upper surface 30A of the electronic substrate 30 and extends in the horizontal direction. In this case, the soldering portion 40 may be configured to connect a portion of the horizontal extension portion 22 with the metal foil terminal portion 42 in the extending direction of the horizontal extension portion 22. In addition, the soldering portion 40 may be configured to connect at least the lower portion of the horizontal extension portion 22 with the metal foil terminal portion 42. In addition, in the present disclosure, the metal foil terminal portion 42 may be, for example, a copper foil terminal portion.

[0072] According to the vehicle-mounted brushless motor device 1, compared with the above-mentioned embodiment in which one end of the coil wire 20 is arranged upward, for example, a larger contact area between the coil wire 20 and the metal foil terminal portion 42 can be ensured, so the coil 18 and the electronic substrate 30 can be easily and reliably connected.

[0073] Figure 7 It is a perspective view schematically showing a modified example of the soldering portion 40 in one embodiment.

[0074] In some embodiments, for example, Figure 4 and Figure 7 As shown, the electronic substrate 30 may include a metal foil terminal portion 42 disposed on the surface (upper surface 30A) on the opposite side of the rotor 12 on the electronic substrate 30, and a protective layer 44 disposed on the metal foil terminal portion 42. Figure 4 As shown, the metal foil terminal portion 42 may be formed over the upper surface 30A, the inner peripheral surface of the through hole 34 , and the lower surface 30B of the electronic substrate 30 . Figure 4 and Figure 7 The protective layer 44 shown has a first opening 46 through which the coil wire 20 passes in the axial direction X, and a second opening 48 which is separated from the first opening 46 and exposes a portion of the metal foil terminal 42. In this case, the soldering portion 40 is configured to connect the metal foil terminal 42 exposed from the second opening 48 to the coil wire 20.

[0075] In general, when soldering is performed, the molten solder spreads and flows in irregular directions, so it is difficult to accurately form the soldering portion 40 in the desired area in many cases. In this regard, according to the vehicle-mounted brushless motor device 1 having a structure in which the metal foil terminal portion 42 exposed from the second opening 48 of the protective layer 44 is connected to the coil wire 20, a step difference is formed along the periphery of the second opening 48 using the thickness of the protective layer 44. Therefore, the molten solder is retained in the second opening 48 and a soldering portion 40 with a stable shape can be formed. As a result, it is possible to effectively suppress the waste of solder and poor connection caused by the flow of solder to an unexpected area (for example, the inside of the through hole 34).

[0076] Next, a method for manufacturing the vehicle-mounted brushless motor device according to one embodiment of the present disclosure will be described. Figure 8 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. Figure 8 As shown, the manufacturing method of the vehicle-mounted brushless motor device 1 includes: step S1, arranging 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, soldering the coil wire 20 protruding from the through hole 34 and the electronic substrate 30.

[0077] 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.

[0078] In step S2, one end of the coil wire 20 can be passed through the through hole 34 by guiding the coil wire 20 along the tapered channel portion 57 as 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.

[0079] 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 may be arranged so that the end faces upward, and a soldering portion 40 may be formed in a manner that fills the gap between the coil wire 20 and the inner peripheral surface 36 of the through hole 34. In addition, the coil wire 20 may be arranged along the metal foil terminal portion 42 arranged adjacent to the through hole 34, and soldering may be performed in a manner that the coil wire 20 is connected to the above-mentioned metal foil terminal portion 42. Furthermore, soldering may be performed in a manner that the metal foil terminal portion 42 is connected to the coil wire 20 on the metal foil terminal portion 42 arranged on the upper surface 30A of the electronic substrate 30, wherein a portion of the metal foil terminal portion 42 is exposed from a first opening portion 46 through which the coil wire 20 passes in the axial direction X, and a second opening portion 48 provided separately from the first opening portion 46.

[0080] According to the manufacturing method of the vehicle-mounted brushless motor device 1, since the electronic substrate 30 and the coil wire 20 arranged on the opposite side of the output side of the brushless motor 10 are directly connected by the soldering portion 40, 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 18 and the electronic substrate 30 are connected via a hard terminal member such as a terminal pin, and thus it is possible to provide 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 18 and the electronic substrate 30 are connected via a hard terminal member such as a terminal pin, the number of soldering positions can be reduced, so that the vehicle-mounted brushless motor device 1 can be easily manufactured.

[0081] 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.

[0082] In addition, as the above-mentioned vehicle-mounted brushless motor device 1, an electric oil pump 1A (oil supply device) equipped with a brushless motor 10 is used as an example for explanation, 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 is arranged on the opposite side of the output side of the brushless motor along a plane intersecting the axial direction of the rotor. The electronic substrate further includes a soldering portion for connecting the coil wire of the coil to the electronic substrate. 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 electronic substrate and the brushless motor and supports the electronic substrate, The electronic substrate includes a through hole penetrating the electronic substrate along the axial direction, The holder includes a guide hole for guiding the coil wire from the brushless motor side to the through hole of the electronic substrate. The electronic substrate is supported by the holder so that a gap is formed in the axial direction between a peripheral portion of the through hole of the electronic substrate and a peripheral portion of the guide hole of the holder arranged below the through hole.

2. The vehicle-mounted brushless motor device according to claim 1, 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.

3. The vehicle-mounted brushless motor device according to claim 2, characterized in that: The guide hole includes a substrate-side channel portion, and the substrate-side channel portion connects an opening end of the guide hole on the electronic substrate side with the tapered channel portion. A channel diameter of the substrate-side channel portion is constant in the axial direction.

4. The vehicle-mounted brushless motor device according to any one of claims 1 to 3, 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.

5. The vehicle-mounted brushless motor device according to any one of claims 1 to 3, characterized in that: The soldering portion connects the coil wire to the inner peripheral surface of the through hole, and the coil wire is provided so as to protrude from the through hole to the opposite side of the rotor on the electronic substrate.

6. A method for manufacturing a brushless motor device for a vehicle, comprising the following steps: The electronic substrate is arranged 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, The electronic substrate includes a through hole penetrating the electronic substrate along the axial direction, And have the following steps: The holder unit is arranged between the electronic substrate and the brushless motor, wherein: The holder unit includes: a connector terminal for connecting the electronic substrate to an external device; and a holder having a guide hole for guiding a coil wire of a coil from the brushless motor side to the through hole of the electronic substrate, the coil constituting the stator of the brushless motor, in which state the coil wire is guided through the guide hole of the holder of the holder unit while passing the coil wire through the through hole of the electronic substrate; and The coil wire protruding from the through hole is soldered to the electronic substrate. The electronic substrate is supported by the holder so that a gap is formed in the axial direction between a peripheral portion of the through hole of the electronic substrate and a peripheral portion of the guide hole of the holder arranged below the through hole.

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