Busbar unit for a motor

Abstract

The present disclosure relates to a busbar unit for a motor, the busbar unit including: a first terminal; a second terminal disposed to be spaced apart from the first terminal in a first direction; a third terminal stacked on the first terminal in a second direction perpendicular to the first direction; a fourth terminal stacked on the second terminal in the second direction; and a holder configured to support the first terminal, the second terminal, the third terminal, and the fourth terminal, thereby obtaining advantageous effects of simplifying a structure and improving design freedom and space utilization.

Description

[0001] Cross-reference to related applications

[0002] This application claims priority and benefit to Korean Patent Application No. 10-2020-0089947, filed on July 21, 2020, with the Korean Intellectual Property Office, the entire contents of which are incorporated herein by reference. Technical Field

[0003] This disclosure relates to a bus unit for a motor, and more specifically, to a bus unit for a motor that can have a simplified structure and improve design freedom and space utilization. Background Technology

[0004] Hybrid vehicles or electric vehicles, also known as environmentally friendly vehicles, generate drive power by using an electric motor (hereinafter referred to as a 'drive motor') that obtains rotational power from electrical energy.

[0005] Typically, a drive motor includes a stator coupled to a housing and a rotor rotatably disposed within the stator, wherein the rotor and stator have a predetermined air gap.

[0006] The stator includes a stator core formed by stacking electrical silicon steel sheets and stator coils wound around the stator core.

[0007] The busbar is located on the upper side of the stator, and the stator coils are connected to an external power source through the busbar.

[0008] The busbar is constructed to include multiple terminals inside the ring retainer, and these terminals are provided by a combination of three phase terminals connected to the U-phase power supply, the V-phase power supply and the W-phase power supply, and a neutral terminal connected to the phase terminals.

[0009] Meanwhile, the busbar is positioned on the upper side of the stator in the axial direction, and the overall height of the motor (the height of the stator in the axial direction) increases with the thickness of the busbar (the thickness of the stator in the axial direction). Therefore, it is necessary to minimize the thickness of the busbar to reduce the size of the motor.

[0010] However, because the four terminals constituting the busbar (U-phase terminal, V-phase terminal, W-phase terminal, and neutral terminal) are stacked vertically in the existing technology, there are limitations in reducing the overall height (vertical thickness) of the busbar. Furthermore, even if the busbar thickness is reduced, sufficient space (height) still needs to be ensured on the upper side of the stator for mounting the busbar, making it difficult to reduce the overall height of the motor.

[0011] Further, in the related art, an overmolded layer for electrical insulation needs to be separately formed on each of the four terminals (the overmolded layer needs to be formed to surround each terminal), and an overmolded housing needs to be additionally formed to surround the entire circumference of the plurality of overmolded layers stacked in the vertical direction. Thus, there is a problem in that the manufacturing process is complicated and cumbersome.

[0012] In addition, in order to secure a surface discharge path for achieving electrical insulation between the respective terminals, it is necessary to secure a predetermined or greater thickness of the overmolded layer. However, since the overall height of the busbar increases as the thickness of the overmolded layer increases, there is a problem in that it is difficult to secure a sufficient thickness of the overmolded layer.

[0013] Accordingly, various types of research have recently been conducted to simplify and miniaturize the structure of the busbar, but the research results still have shortcomings. Therefore, there is a need to develop a busbar having a simplified and miniaturized structure. SUMMARY

[0014] An object of the disclosure is to provide a busbar unit for a motor, which can have a simplified structure and can improve design freedom and space utilization.

[0015] Another object of the disclosure is to minimize the thickness of the busbar unit and to contribute to miniaturization of the motor.

[0016] Still another object of the disclosure is to simplify the manufacturing process and to reduce the manufacturing time.

[0017] Still another object of the disclosure is to improve electrical insulation performance and to improve stability and reliability.

[0018] The objects achieved by the exemplary embodiments are not limited to the above-mentioned objects, and include objects or effects that can be identified from the following schemes or exemplary embodiments.

[0019] To achieve the above object of the disclosure, an exemplary embodiment of the disclosure provides a busbar unit for a motor, including: a first terminal; a second terminal disposed to be spaced apart from the first terminal in a first direction; a third terminal stacked on the first terminal in a second direction perpendicular to the first direction; a fourth terminal stacked on the second terminal in the second direction; and a holder configured to support the first terminal, the second terminal, the third terminal, and the fourth terminal.

[0020] This is to simplify the structure of the busbar unit and to improve design freedom and space utilization.

[0021] That is, the busbar is disposed at the upper side (or lower side) of the stator in the axial direction of the stator, and the overall height (height in the axial direction of the stator) of the motor increases as the thickness (thickness in the axial direction of the stator) of the busbar increases. Therefore, in order to miniaturize the motor, it is necessary to minimize the thickness of the busbar.

[0022] However, because the plurality of terminals (U-phase terminal, V-phase terminal, W-phase terminal, and neutral terminal) constituting the busbar are stacked in the vertical direction in the related art, there is a limit in reducing the overall height (vertical thickness) of the busbar. In addition, since it is necessary to secure a space (height) for disposing the busbar at the upper side of the stator even if the thickness of the busbar is reduced, there is a problem in that it is difficult to reduce the overall height of the motor.

[0023] However, according to an exemplary embodiment of the disclosure, the first terminal and the second terminal are arranged in a first direction, and the third terminal and the fourth terminal are arranged on the first terminal and the second terminal in a second direction perpendicular to the first direction. In other words, arranged in a 2x2 matrix. Therefore, it is possible to minimize the thickness of the busbar unit.

[0024] Therefore, the following advantageous effects can be obtained: improvement in space utilization in the area above the stator, improvement in design freedom, minimization of an increase in the size of the motor caused by installation of the busbar unit for implementing a control circuit of the motor, and thus contribution to miniaturization of the motor.

[0025] The first terminal, the second terminal, the third terminal, and the fourth terminal can have various structures according to required conditions and design specifications.

[0026] According to an exemplary embodiment of the disclosure, the first terminal can include a first body and a first terminal part extending from the first body and exposed from an upper surface of the holder, the second terminal can include a second body and a second terminal part extending from the second body and exposed from the upper surface of the holder, the third terminal can include a third body and a third terminal part extending from the third body and exposed from the upper surface of the holder, and the fourth terminal can include a fourth body and a fourth terminal part extending from the fourth body and exposed from the upper surface of the holder.

[0027] The structure of the holder can be variously changed according to required conditions and design specifications.

[0028] According to an exemplary embodiment of the disclosure, the holder can include an overmold layer formed to surround the first terminal and the second terminal, and an overmold case formed to surround the overmold layer, the third terminal, and the fourth terminal.

[0029] As described above, in the exemplary embodiment of the present disclosure, since the holder is constituted by only a single overmolding layer and a single overmolding case, advantageous effects of simplifying the structure of the holder, simplifying the process of manufacturing the holder, and reducing the manufacturing time can be obtained.

[0030] That is, in the prior art, the overmolding layer for electrical insulation needs to be separately formed on each of the four terminals (the overmolding layer needs to be formed to surround each terminal), and the overmolding case needs to be additionally formed to surround the entire circumference of the plurality of overmolding layers stacked in the vertical direction. Therefore, there is a problem that the manufacturing process is complicated and cumbersome. In addition, in the prior art, since the overall height of the busbar increases as the thickness of the overmolding layer increases, there is a problem that it is difficult to secure a sufficient thickness of the overmolding layer.

[0031] However, according to the exemplary embodiment of the present disclosure, the holder can be formed through only two injection molding processes (a process of overmolding layer injection molding and a process of overmolding case injection molding), and thus, advantageous effects of securing electrical insulation performance, simplifying the structure of the holder, and simplifying the process of manufacturing the holder can be obtained.

[0032] According to the exemplary embodiment of the present disclosure, the busbar unit for a motor can include a spacer inserted between the first terminal and the second terminal and the third terminal and the fourth terminal.

[0033] As described above, since the spacer is inserted between the first terminal and the second terminal arranged in the first layer and the third terminal and the fourth terminal arranged in the second layer, a sufficient interval can be secured between the first terminal and the third terminal, and a sufficient interval can be secured between the second terminal and the fourth terminal, thereby electrical insulation performance between the first terminal and the third terminal and insulation performance between the second terminal and the fourth terminal can be secured. Therefore, advantageous effects of minimizing poor insulation between the first terminal and the third terminal (between the second terminal and the fourth terminal) and improving stability and reliability can be obtained.

[0034] Specifically, the spacer can be inserted between the overmolding layer and the third terminal and the fourth terminal.

[0035] According to the exemplary embodiment of the present disclosure, the busbar unit for a motor can include a guide protrusion formed on the spacer, and a guide groove formed in the overmolding layer to receive the guide protrusion.

[0036] As described above, when the spacer is seated on the overmolding layer, the guide protrusion is received (inserted) in the guide groove, and thus, advantageous effects of preventing the spacer from rotating and moving with respect to the overmolding layer and stably maintaining a state in which the spacer is disposed can be obtained.

[0037] In addition, since the guide protrusion is formed on the spacer and the guide groove is formed in the overmold layer, the spacer can be seated on the upper portion of the overmold layer (in close contact therewith) only in a state in which the spacer is aligned with the overmold layer at a certain position (in the vertical direction), thereby improving the accuracy of assembling the spacer and easily identifying whether the spacer is assembled incorrectly.

[0038] In detail, the guide protrusion can include a first guide protrusion formed adjacent to an inner circumferential surface of the spacer and a second guide protrusion spaced apart from the first guide protrusion in a circumferential direction of the spacer and formed adjacent to an outer circumferential surface of the spacer, and the guide groove can include a first guide groove configured to receive the first guide protrusion and a second guide groove configured to receive the second guide protrusion.

[0039] According to an exemplary embodiment of the disclosure, the spacer can have a through-hole through which the first terminal portion and the second terminal portion pass.

[0040] According to an exemplary embodiment of the disclosure, the spacer can include a first seating portion on which the third terminal is seated and a second seating portion on which the fourth terminal is seated.

[0041] As described above, since the spacer has the first seating portion and the second seating portion, an advantageous effect of stably maintaining a state in which the third terminal and the third terminal are seated can be obtained.

[0042] In detail, the first seating portion and the second seating portion can be recessed into an upper surface of the spacer.

[0043] According to an exemplary embodiment of the disclosure, a boundary rib can be disposed between the first seating portion and the second seating portion. As described above, since the boundary rib is formed along a boundary between the first seating portion and the second seating portion, an advantageous effect of more stably maintaining a state in which the third terminal and the fourth terminal are seated on the first seating portion and the second seating portion and securing an electrical insulation performance between the third terminal and the fourth terminal can be obtained.

[0044] According to an exemplary embodiment of the disclosure, the busbar unit for a motor can include a coil support unit disposed on an upper portion of the holder and configured to support a coil of the stator.

[0045] As an example, the coil support unit can have a coil receiving groove that receives the coil. BRIEF DESCRIPTION OF DRAWINGS

[0046] Figure 1 FIG. 1 is a perspective view showing a busbar unit for a motor according to an exemplary embodiment of the disclosure.

[0047] Figure 2 is an exploded perspective view for explaining a busbar unit for a motor according to an exemplary embodiment of the present disclosure.

[0048] Figure 3 is a top view showing a busbar unit for a motor according to an exemplary embodiment of the present disclosure.

[0049] Figure 4 is a cross-sectional view taken along line 'I-I' in Figure 3 .

[0050] Figure 5 is a view for explaining a first terminal of a busbar unit for a motor according to an exemplary embodiment of the present disclosure.

[0051] Figure 6 is a view for explaining a second terminal of a busbar unit for a motor according to an exemplary embodiment of the present disclosure.

[0052] Figure 7 is a view for explaining a third terminal of a busbar unit for a motor according to an exemplary embodiment of the present disclosure.

[0053] Figure 8 is a view for explaining a fourth terminal of a busbar unit for a motor according to an exemplary embodiment of the present disclosure.

[0054] Figure 9 is a view for explaining a spacer of a busbar unit for a motor according to an exemplary embodiment of the present disclosure.

[0055] Figure 10 is a view for explaining an overmolding layer of a busbar unit for a motor according to an exemplary embodiment of the present disclosure.

[0056] Figure 11 is a view for explaining a structure in which a spacer of a busbar unit for a motor according to an exemplary embodiment of the present disclosure is disposed.

[0057] Figure 12 and Figure 13 is a view for explaining a guide protrusion and a guide groove of a busbar unit for a motor according to an exemplary embodiment of the present disclosure.

[0058] Figure 14 is a view for explaining a third terminal and a fourth terminal seated on a spacer of a busbar unit for a motor according to an exemplary embodiment of the present disclosure.

[0059] Figure 15 is a view for explaining an overmolding housing of a busbar unit for a motor according to an exemplary embodiment of the present disclosure.

[0060] Figure 16 FIG. 1 is a view for explaining a coil support unit of a bus bar unit for a motor according to an exemplary embodiment of the present disclosure. DETAILED DESCRIPTION

[0061] Hereinafter, exemplary embodiments of the present disclosure will be described in detail with reference to the accompanying drawings.

[0062] However, the technical spirit of the present disclosure is not limited to some exemplary embodiments described herein, but can be implemented in various different ways. One or more of the constituent elements in the exemplary embodiments can be selectively combined and replaced within the scope of the technical spirit of the present disclosure.

[0063] In addition, unless clearly and specifically defined and stated otherwise, the terms used in the exemplary embodiments of the present disclosure, including technical and scientific terms, can be interpreted as having a meaning that can be commonly understood by one of ordinary skill in the art to which the present disclosure pertains. The meaning of the commonly used terms, such as those defined in a dictionary, can be interpreted in accordance with the context of the relevant technology.

[0064] In addition, the terms used in the exemplary embodiments of the present disclosure are used to explain the exemplary embodiments, and are not intended to limit the present disclosure.

[0065] In the context of the present specification, the singular form can include the plural form unless specifically stated or defined otherwise. The expression "at least one of (or one or more of) A, B, and C" described herein can include one or more of all combinations of A, B, and C that can be formed by combining A, B, and C.

[0066] In addition, terms such as first, second, A, B, a, and b can be used to describe the constituent elements of the exemplary embodiments of the present disclosure.

[0067] These terms are used only for the purpose of distinguishing one constituent element from another constituent element, and the nature, sequence, or order of the constituent elements is not limited by these terms.

[0068] Further, when one constituent element is described as being "connected," "coupled," or "attached" to another constituent element, the one constituent element can be directly connected, coupled, or attached to the other constituent element, or can be connected, coupled, or attached to the other constituent element through yet another constituent element interposed therebetween.

[0069] Also, the expression "one constitutional element is formed above (on) or below (under) another constitutional element" includes not only a case where the two constitutional elements directly contact each other, but also a case where one or more other constitutional elements are formed or disposed between the two constitutional elements. Also, the expressions "above (on) or below (under)" can include the meaning based on the downward direction and the upward direction of one constitutional element.

[0070] Reference Figures 1 to 16 A busbar unit 10 for a motor according to an exemplary embodiment of the present disclosure includes a first terminal 110, a second terminal 120 disposed to be spaced apart from the first terminal 110 in a first direction, a third terminal 130 stacked on the first terminal 110 in a second direction perpendicular to the first direction, a fourth terminal 140 stacked on the second terminal 120 in the second direction, and a holder 200 configured to support the first terminal 110, the second terminal 120, the third terminal 130, and the fourth terminal 140.

[0071] For reference, the busbar unit 10 for a motor according to an exemplary embodiment of the present disclosure can be installed on various types of motors according to required conditions and design specifications, and the present disclosure is not restricted or limited by the type and structure of the motor.

[0072] As an example, a motor to which the busbar unit 10 according to an exemplary embodiment of the present disclosure is applied can be used as a driving motor for an environmentally friendly vehicle such as a hybrid vehicle and / or an electric vehicle, which obtains driving power from electric energy.

[0073] For example, the driving motor is a synchronous motor of an inner rotor type, and includes a stator (not shown) installed in a motor housing (not shown) and a rotor (not shown) rotatably installed in the stator, in which the rotor has a predetermined air gap from the stator. The busbar unit 10 according to an exemplary embodiment of the present disclosure can be connected to the stator.

[0074] The stator can be received in the housing (not shown), and the coil 60 is configured to cause electrical interaction between the stator and the rotor, and to wind the stator.

[0075] As an example, the stator includes a plurality of split cores (not shown) disposed to collectively define a ring shape, and a support ring (not shown) disposed to surround an outer circumferential surface of the plurality of split cores.

[0076] The split cores can be variously changed in number and structure according to required conditions and design specifications, and the present disclosure is not restricted or limited by the number of split cores and the split core structure.

[0077] More specifically, the split cores can be formed by stacking a plurality of electrical steel sheets in an axial direction of the rotor.

[0078] A bobbin (not shown) (e.g., made of plastic) is provided around each split core, and a coil (see 60 in FIG. 1) is wound on the bobbin. Figure 15

[0079] According to another exemplary embodiment of the present disclosure, the stator can be configured of only one core.

[0080] The rotor is provided to rotate by electrical interaction between the stator and the rotor.

[0081] As an example, the rotor can include a rotor core (not shown) and magnets (not shown). The rotor core can be configured by stacking a plurality of circular plates in the form of thin steel plates or in the form of a cylinder.

[0082] A hole (not shown) to which a shaft is coupled can be formed at the center of the rotor. A protrusion (not shown) to guide the magnets can protrude from the outer circumferential surface of the rotor core. The magnets can be attached to the outer circumferential surface of the rotor core to be spaced apart from each other by a predetermined interval in the circumferential direction of the rotor core.

[0083] In addition, the rotor can include a can member (not shown) provided to surround the magnets to prevent the magnets from being deviated.

[0084] The bus bar unit 10 can be provided at the upper side of the stator and can include a first terminal 110, a second terminal 120, a third terminal 130, a fourth terminal 140, and a holder 200.

[0085] The first terminal 110, the second terminal 120, the third terminal 130, and the fourth terminal 140 are provided to electrically connect the coils 60 of the stator and an external power source.

[0086] Referring to Figures 5 to 8 , each of the first terminal 110, the second terminal 120, the third terminal 130, and the fourth terminal 140 can be at least one of phase terminals (a U-phase terminal, a V-phase terminal, and a W-phase terminal) connected to a U-phase power source, a V-phase power source, and a W-phase power source and a neutral terminal configured to electrically connect the phase terminals.

[0087] As an example, the first terminal 110 can be a U-phase terminal, the second terminal 120 can be a neutral terminal, the third terminal 130 can be a V-phase terminal, and the fourth terminal 140 can be a W-phase terminal. According to another exemplary embodiment of the present disclosure, the first terminal can be any one of other terminals (e.g., a neutral terminal, a V-phase terminal, and a W-phase terminal).

[0088] ​More specifically, the first terminal 110 can include a first body 112 and first terminal portions 114, wherein the first body is configured to be received in the holder 200, and each of the first terminal portions extends (bends) from an inner circumferential surface of the first body 112 and protrudes upward from the holder 200.

[0089] The first body 112 can be variously changed in structure and shape according to a required condition and design specification. As an example, the first body 112 can have a single layer structure and can be formed in the form of a belt member having a predetermined diameter of a ring (or an arc).

[0090] According to another exemplary embodiment of the present disclosure, the first body can have a double layer structure (a multi layer structure) having a bent portion.

[0091] The first terminal portions 114 are connected to the inner circumferential surface of the first body 112 and protrude upward from the first body 112, and the coils 60 of the stator can be connected to (welded to) the first terminal portions 114.

[0092] The first terminal portions 114 can have various structures to which the end portions of the coils 60 can be connected, and the present disclosure is not restricted or limited by the structure and shape of the first terminal portions 114.

[0093] As an example, the first terminal portions 114 can have a substantially 'U' shaped terminal groove (not shown) which can receive the end portions of the coils 60. In a state in which the end portions of the coils 60 are fitted into the terminal groove, the end portions of the coils 60 can be integrally connected (electrically connected) to the first terminal portions 114 by being welded to the first terminal portions 114.

[0094] In addition, the first terminal 110 can include a first power terminal portion 116 which protrudes from an outer circumferential surface of the first body 112.

[0095] The first power terminal portion 116 is provided to extend from the outer circumferential surface of the first body 112 and protrude from the outer circumferential surface of the holder 200. An external power cable having a phase (e.g., a U phase) corresponding to the first power terminal portion 116 can be electrically connected to the first power terminal portion 116.

[0096] The second terminal 120 is provided to be spaced apart from the first terminal 110 in the first direction.

[0097] As an example, the second terminal 120 can be provided to be spaced apart from the first terminal 110 in a horizontal direction (the first direction) corresponding to a radial direction of the first terminal 110.

[0098] In an exemplary embodiment of the present disclosure, an example has been described in which the radial direction of the first terminal 110 is oriented in the horizontal direction, and the horizontal direction is defined as the first direction. However, according to another exemplary embodiment of the present disclosure, a vertical direction or other direction can be defined as the first direction.

[0099] More specifically, the second terminal 120 can include a second body 122 and second terminal portions 124, wherein the second body is configured to be received in the holder 200, and each of the second terminal portions extends (bends) from an outer circumferential surface of the second body 122 and protrudes upward from the holder 200.

[0100] The second body 122 can be variously changed in structure and shape according to a required condition and design specification. As an example, the second body 122 can have a single layer structure and can be formed as a belt member in the form of a ring (or an arc) having a smaller diameter than the first body 112.

[0101] According to another exemplary embodiment of the present disclosure, the second body can have a double layer structure (a multi layer structure) having a bent portion.

[0102] The second terminal portions 124 are connected to the outer circumferential surface of the second body 122 and protrude upward from the second body 122, and the coils 60 of the stator can be connected to (welded to) the second terminal portions 124.

[0103] The second terminal portions 124 can have various structures to which the end portions of the coils 60 can be connected, and the present disclosure is not restricted or limited by the structure and shape of the second terminal portions 124.

[0104] As an example, the second terminal portions 124 can have a substantially 'U' shaped terminal groove (not shown) that can receive the end portions of the coils 60. In a state in which the end portions of the coils 60 are fitted into the terminal groove, the end portions of the coils 60 can be integrally connected (electrically connected) to the second terminal portions 124 by being welded to the second terminal portions 124.

[0105] The third terminal 130 is provided to be stacked on the first terminal 110 in the second direction.

[0106] In this case, the configuration in which the third terminal 130 is stacked on the first terminal 110 in the second direction is defined as a configuration including the third terminal 130 being stacked on the upper portion or the lower portion of the first terminal 110 in the second direction.

[0107] As an example, the third terminal 130 can be stacked on the upper portion of the first terminal 110 in the second direction (e.g., a vertical direction) perpendicular to the first direction (e.g., a horizontal direction) based on Figure 4 ).

[0108] More specifically, the third terminal 130 can include a third body 132 and third terminal portions 134, wherein the third body is configured to be received in the holder 200, and each of the third terminal portions extends (bends) from an inner circumferential surface of the third body 132 and protrudes upward from the holder 200.

[0109] The third body 132 can be variously changed in structure and shape according to a required condition and design specification. As an example, the third body 132 can have a single layer structure and can be formed in the form of a belt member having a predetermined diameter of a ring (or an arc). Specifically, the third body 132 can have a diameter corresponding to that of the first body 112.

[0110] According to another exemplary embodiment of the present disclosure, the third body can have a double layer structure (a multi layer structure) having a bent portion.

[0111] The third terminal portions 134 are connected to the inner circumferential surface of the third body 132 and protrude upward from the third body 132, and the coils 60 of the stator can be connected to (welded to) the third terminal portions 134.

[0112] The third terminal portions 134 can have various structures to which the end portions of the coils 60 can be connected, and the present disclosure is not bound or limited by the structure and shape of the third terminal portions 134.

[0113] As an example, the third terminal portions 134 can have a substantially 'U' shaped terminal groove (not shown) that can receive the end portions of the coils 60. In a state in which the end portions of the coils 60 are fitted into the terminal groove, the end portions of the coils 60 can be integrally connected (electrically connected) to the third terminal portions 134 by being welded to the third terminal portions 134.

[0114] In addition, the third terminal 130 can include a third power terminal portion 136 protruding from an outer circumferential surface of the third body 132.

[0115] The third power terminal portion 136 is provided to extend from the outer circumferential surface of the third body 132 and protrude from the outer circumferential surface of the holder 200. An external power cable having a phase (for example, a V phase) corresponding to the third power terminal portion 136 can be electrically connected to the third power terminal portion 136.

[0116] The fourth terminal 140 is provided to be stacked on the second terminal 120 in the second direction.

[0117] In this case, the configuration in which the fourth terminal 140 is stacked on the second terminal 120 in the second direction is defined as a configuration including the fourth terminal 140 being stacked on the upper portion or the lower portion of the second terminal 120 in the second direction.

[0118] As an example, the fourth terminal 140 can be stacked on an upper portion of the second terminal 120 in a second direction (e.g., a vertical direction) perpendicular to a first direction (e.g., a horizontal direction) (based on Figure 4 ).

[0119] More specifically, the fourth terminal 140 can include a fourth body 142 configured to be received in the holder 200, and fourth terminal portions 144 each extending (bending) from an outer circumferential surface of the fourth body 142 and protruding upward from the holder 200.

[0120] The fourth body 142 can be variously changed in structure and shape according to a required condition and design specification. As an example, the fourth body 142 can have a single layer structure and can be formed in the form of a belt member having a predetermined diameter of a ring (or an arc). In particular, the fourth body 142 can have a diameter corresponding to that of the second body 122.

[0121] According to another exemplary embodiment of the present disclosure, the fourth body can have a double layer structure (a multi layer structure) having a bending portion.

[0122] The fourth terminal portions 144 are connected to the outer circumferential surface of the fourth body 142 and protrude upward from the fourth body 142, and the coils 60 of the stator can be connected to (welded to) the fourth terminal portions 144.

[0123] The fourth terminal portions 144 can have various structures to which the end portions of the coils 60 can be connected, and the present disclosure is not bound or limited by the structure and shape of the fourth terminal portions 144.

[0124] As an example, the fourth terminal portions 144 can have a terminal groove (not shown) having a substantially 'U' shape, which can receive the end portions of the coils 60. In a state in which the end portions of the coils 60 are fitted into the terminal groove, the end portions of the coils 60 can be integrally connected (electrically connected) to the fourth terminal portions 144 by being welded to the fourth terminal portions 144.

[0125] In addition, the fourth terminal 140 can include fourth power terminal portions 146 protruding from the outer circumferential surface of the fourth body 142.

[0126] The fourth power terminal portions 146 are provided to extend from the outer circumferential surface of the fourth body 142 and protrude from the outer circumferential surface of the holder 200. An external power cable having a phase (e.g., a W phase) corresponding to the fourth power terminal portions 146 can be electrically connected to the fourth power terminal portions 146.

[0127] As described above, according to an exemplary embodiment of the present disclosure, the first terminal 110 and the second terminal 120 are arranged in a first direction, and the third terminal 130 and the fourth terminal 140 are arranged on upper portions of the first terminal 110 and the second terminal 120 in a second direction perpendicular to the first direction. In other words, the first terminal 110, the second terminal 120, the third terminal 130, and the fourth terminal 140 are arranged in a 2x2 matrix. Accordingly, it is possible to minimize the thickness of the busbar unit 10.

[0128] Accordingly, the following advantageous effects can be obtained: improvement in space utilization in an area above the stator in which the busbar unit 10 is disposed, improvement in design freedom, minimization of an increase in the size of the motor caused by installation of the busbar unit 10 for implementing a control circuit of the motor, and thus contribution to miniaturization of the motor.

[0129] The holder 200 is provided to provide support in a state in which the first terminal 110, the second terminal 120, the third terminal 130, and the fourth terminal 140 are disposed, and to electrically insulate the first terminal 110, the second terminal 120, the third terminal 130, and the fourth terminal 140.

[0130] The holder 200 can be variously changed in material and shape according to a required condition and design specification, and the present disclosure is not bound or limited by the material and shape of the holder 200.

[0131] As an example, the holder 200 can be formed in a shape of a hollow ring and provided as a molded product (e.g., made of an insulating material) formed by injection molding.

[0132] According to an exemplary embodiment of the present disclosure, the holder 200 can include an overmold layer 210 formed to surround the first terminal 110 and the second terminal 120, and an overmold case 220 formed to surround the overmold layer 210, the third terminal 130, and the fourth terminal 140.

[0133] Referring to Figure 4 and Figure 10 , the overmold layer 210 is formed to surround the first terminal 110 and the second terminal 120 arranged in the first direction.

[0134] More specifically, the overmold layer 210 can be injection molded in the form of a hollow ring, which integrally surrounds the first body 112 and the second body 122, and the first terminal portion 114 and the second terminal portion 124 can be exposed upward from the overmold layer 210.

[0135] Referring to Figure 4 and Figure 14The overmolded case 220 is formed to surround the overmolded layer 210, the third terminal 130, and the fourth terminal 140 in a state in which the third terminal 130 and the fourth terminal 140 are stacked on an upper portion of the overmolded layer 210.

[0136] More specifically, the overmolded case 220 can be injection-molded in the form of a ring that integrally surrounds the overmolded layer 210, the third terminal 130, and the fourth terminal 140. The first terminal portion 114, the second terminal portion 124, the third terminal portion 134, and the fourth terminal portion 144 can be exposed upward from the overmolded case 220.

[0137] As described above, in the example embodiment of the disclosure, since the holder 200 is constituted only by the single overmolded layer 210 and the single overmolded case 220, the following advantageous effects can be obtained: simplification of the structure of the holder 200, simplification of the process of manufacturing the holder 200, and reduction of the manufacturing time.

[0138] That is, in the related art, the overmolded layer for electrical insulation needs to be separately formed on each of the four terminals (the overmolded layer needs to be formed to surround each terminal), and the overmolded case needs to be additionally formed to surround the entire circumference of the plurality of overmolded layers stacked in the vertical direction. Therefore, there is a problem that the manufacturing process is complicated and cumbersome. In addition, in the related art, since the overall height of the busbar increases as the thickness of the overmolded layer increases, there is a problem that it is difficult to secure a sufficient thickness of the overmolded layer.

[0139] However, according to the example embodiment of the disclosure, the holder 200 can be formed through only two injection molding processes (a process of overmolded layer injection molding and a process of overmolded case injection molding), and thus, the following advantageous effects can be obtained: securing of electrical insulation performance, simplification of the structure of the holder 200, and simplification of the process of manufacturing the holder 200.

[0140] Referring to Figure 4 , Figure 9 and Figures 11 to 13 , the busbar unit 10 for a motor according to the example embodiment of the disclosure can include a spacer 300 interposed between the first terminal 110 and the second terminal 120 and the third terminal 130 and the fourth terminal 140.

[0141] The spacer 300 is provided to secure a surface discharge path for implementing electrical insulation between the first terminal 110 and the third terminal 130 and a surface discharge path for implementing electrical insulation between the second terminal 120 and the fourth terminal 140.

[0142] That is, since the spacer 300 is interposed between the first and second terminals 110 and 120 arranged in the first layer and the third and fourth terminals 130 and 140 arranged in the second layer, sufficient spacing can be ensured between the first and third terminals 110 and 130, and sufficient spacing can be ensured between the second and fourth terminals 120 and 140, thereby ensuring the electrical insulation performance between the first and third terminals 110 and 130 and the insulation performance between the second and fourth terminals 120 and 140. Accordingly, the following advantageous effects can be obtained: minimizing poor insulation between the first and third terminals 110 and 130 (between the second and fourth terminals) and improving stability and reliability.

[0143] As an example, the spacer 300 can be formed in a shape having a hollow ring and provided as a molded product (e.g., made of an electrically insulating material) formed by injection molding.

[0144] In particular, the spacer 300 can be interposed between the overmold layer 210 and the third and fourth terminals 130 and 140.

[0145] According to another exemplary embodiment of the present disclosure, the spacer can be disposed over the first and second terminals before the overmold layer is formed, and then the overmold layer can be formed to surround the first, second, and spacer.

[0146] Referring to Figure 12 and Figure 13 , the busbar unit 10 for a motor according to an exemplary embodiment of the present disclosure can include a guide protrusion 310 and a guide groove 212, wherein the guide protrusion is formed on a bottom surface of the spacer 300 facing an upper surface of the overmold layer 210, and the guide groove is formed in the upper surface of the overmold layer 210 and configured to receive the guide protrusion 310.

[0147] The guide protrusion 310 and the guide groove 212 can have various structures according to required conditions and design specifications, and the present disclosure is not bound or limited by the structures and numbers of the guide protrusion 310 and the guide groove 212.

[0148] According to another exemplary embodiment of the present disclosure, the guide groove can be formed in the spacer, and the guide protrusion can be formed on the overmold layer.

[0149] As described above, when the spacer 300 is seated on the overmold layer 210, the guide protrusion 310 is received (interposed) in the guide groove 212, and thus, the following advantageous effects can be obtained: preventing the spacer 300 from rotating and moving with respect to the overmold layer 210 and stably maintaining the state in which the spacer 300 is disposed.

[0150] In addition, since the guide protrusion 310 is formed on the spacer 300 and the guide groove 212 is formed in the overmold layer 210, the spacer 300 can be seated on the upper portion of the overmold layer 210 (in close contact therewith) only in a state in which the spacer 300 is aligned with the overmold layer 210 at a position (in the vertical direction), thereby improving accuracy in assembling the spacer 300 and easily identifying whether the spacer 300 is assembled incorrectly.

[0151] In detail, the guide protrusion 310 can include a first guide protrusion 310a formed adjacent to an inner circumferential surface of the spacer 300 and a second guide protrusion 310b spaced apart from the first guide protrusion 310a in a circumferential direction of the spacer 300 and formed adjacent to an outer circumferential surface of the spacer 300. The guide groove 212 can include a first guide groove 212a configured to receive the first guide protrusion 310a and a second guide groove 212b configured to receive the second guide protrusion 310b.

[0152] As described above, since the first guide protrusion 310a and the second guide protrusion 310b spaced apart from each other are received in the first guide groove 212a and the second guide groove 212b, an advantageous effect of more effectively preventing the spacer 300 from rotating and moving with respect to the overmold layer 210 can be obtained.

[0153] According to an exemplary embodiment of the present disclosure, the spacer 300 can have a through-hole 320 through which the first terminal portion 114 and the second terminal portion 124 exposed (protrude) upward from the overmold layer 210 can pass, thereby being exposed upward from the spacer 300 in a state in which the spacer 300 is seated on the upper portion of the overmold layer 210.

[0154] Referring to Figure 4 and Figure 14 According to an exemplary embodiment of the present disclosure, the spacer 300 can include a first seating portion 350 on which the third terminal 130 is seated and a second seating portion 330 on which the fourth terminal 140 is seated.

[0155] The first seating portion 350 and the second seating portion 330 can have various structures capable of stably maintaining a state in which the third terminal 130 and the fourth terminal 140 are seated, and the present disclosure is not bound and limited by the shape and structure of the first seating portion 350 and the second seating portion 330.

[0156] As an example, the first seating portion 350 and the second seating portion 330 can be recessed into the upper surface of the spacer 300.

[0157] According to another exemplary embodiment of the disclosure, the first seating portion and the second seating portion can protrude from the upper surface of the spacer, or only either of the first seating portion and the second seating portion can be recessed into or protrude from the upper surface of the spacer.

[0158] In detail, the boundary rib 340 can be provided between the first seating portion 350 and the second seating portion 330. As an example, the boundary rib 340 can be formed in the form of a ring continuously formed along the boundary between the first seating portion 350 and the second seating portion 330.

[0159] As described above, since the boundary rib 340 is formed along the boundary between the first seating portion 350 and the second seating portion 330, the following advantageous effects can be obtained: a state in which the third terminal 130 and the fourth terminal 140 are seated on the first seating portion 350 and the second seating portion 330 is more stably maintained, and electrical insulation performance between the third terminal 130 and the fourth terminal 140 is secured.

[0160] Meanwhile, referring to Figure 16 According to an exemplary embodiment of the disclosure, the busbar unit 10 for a motor can include a coil support unit 230 provided on an upper portion of the holder 200 to support the coil 60 of the stator.

[0161] When the end portion of the coil 60 wound around the stator is formed toward the first terminal portion 114 (the second terminal portion, the third terminal portion, or the fourth terminal portion) (when the end portion of the coil 60 is formed in the radial direction of the stator), the coil support unit 230 is provided to support the coil 60 in a precise direction and a precise angle.

[0162] The coil support unit 230 can have various structures capable of supporting the coil 60 of the stator, and the disclosure is not restricted or limited by the shape and structure of the coil support unit 230.

[0163] As an example, the coil support unit 230 can have a coil receiving groove 232 that receives the coil 60.

[0164] In detail, the coil support unit 230 is formed to correspond to the first terminal portion 114 (the second terminal portion, the third terminal portion, or the fourth terminal portion) in the radial direction of the first body 112.

[0165] In this case, the configuration in which the coil support unit 230 is formed to correspond to the first terminal portion 114 in the radial direction of the first body 112 means that the coil support unit 230 and the first terminal portion 114 are disposed on substantially the same line in the radial direction of the first body 112.

[0166] As described above, since the coil support unit 230 is provided to correspond to the first terminal portion 114 in the radial direction of the first body 112, an advantageous effect of more accurately guiding and supporting the end portion of the coil 60 on the first terminal portion 114 can be obtained.

[0167] Although the exemplary embodiments have been described above, the exemplary embodiments are merely illustrative and not intended to limit the present disclosure. It will be understood by those skilled in the art that various changes and modifications can be made to the exemplary embodiments described above without departing from the essential features of the present exemplary embodiments. For example, the respective constituent elements specifically described in the exemplary embodiments can be changed and then implemented. Furthermore, it should be understood that differences with respect to changes and modifications are included in the scope of the present disclosure defined by the appended claims.

[0168] According to the exemplary embodiments of the present disclosure as described above, an advantageous effect of simplifying the structure and improving the design freedom and the space utilization can be obtained.

[0169] In particular, according to the exemplary embodiments of the present disclosure, an advantageous effect of minimizing the thickness of the bus bar unit and contributing to the miniaturization of the motor can be obtained.

[0170] In addition, according to the exemplary embodiments of the present disclosure, an advantageous effect of simplifying the manufacturing process and reducing the manufacturing time can be obtained.

[0171] In addition, according to the exemplary embodiments of the present disclosure, an advantageous effect of improving the electrical insulation performance and improving the stability and reliability can be obtained.

[0172] Elements of the drawings

[0173] 10: bus bar unit

[0174] 60: coil

[0175] 110: first terminal

[0176] 112: first body

[0177] 114: first terminal portion

[0178] 116: first power terminal portion

[0179] 120: second terminal

[0180] 122: second body

[0181] 124: second terminal portion

[0182] 130: third terminal

[0183] 132: third body

[0184] 134: third terminal portion

[0185] 136: third power terminal portion

[0186] 140: fourth terminal

[0187] 142: fourth main body

[0188] 144: fourth terminal portion

[0189] 146: fourth power terminal portion

[0190] 200: holder

[0191] 210: overmolding layer

[0192] 212: guide groove

[0193] 212a: first guide groove

[0194] 212b: second guide groove

[0195] 220: overmolding housing

[0196] 230: coil support unit

[0197] 232: coil receiving groove

[0198] 300: spacer

[0199] 310: guide protrusion

[0200] 310a: first guide protrusion

[0201] 310b: second guide protrusion

[0202] 320: through hole

[0203] 330: second seating portion

[0204] 340: boundary rib

[0205] 350: first seating portion

Claims

1. A bus bar unit for a motor, the bus bar unit comprising: a first terminal; a second terminal disposed to be spaced apart from the first terminal in a first direction; a third terminal stacked on the first terminal in a second direction perpendicular to the first direction; a fourth terminal stacked on the second terminal in the second direction; a holder configured to support the first terminal, the second terminal, the third terminal, and the fourth terminal, the holder including an overmold layer formed to surround the first terminal and the second terminal; and a spacer inserted between the first terminal and the second terminal and the third terminal and the fourth terminal, wherein the spacer is inserted between the overmold layer and the third terminal and the fourth terminal.

2. The busbar unit of claim 1, wherein, The holder includes: an overmold housing formed to surround the overmold layer, the third terminal, and the fourth terminal. 3.The bus bar unit of claim 2, comprising: a guide protrusion formed on the spacer; and a guide groove formed in the overmold layer to receive the guide protrusion. The guide protrusion includes:

4. The busbar unit of claim 3, wherein, a first guide protrusion formed adjacent to an inner circumferential surface of the spacer; and a second guide protrusion spaced apart from the first guide protrusion in a circumferential direction of the spacer and formed adjacent to an outer circumferential surface of the spacer, and wherein the guide groove includes: a first guide groove configured to receive the first guide protrusion; and a second guide groove configured to receive the second guide protrusion. The spacer is made of an electrically insulating material.

5. The busbar unit of claim 2, wherein, 6.The bus bar unit of claim 2, comprising: a first seating portion provided on the spacer such that the third terminal is seated on the first seating portion; and a second seating portion provided on the spacer such that the fourth terminal is seated on the second seating portion. At least one of the first seating portion and the second seating portion is recessed into an upper surface of the spacer. A boundary rib is provided between the first seating portion and the second seating portion.

7. The busbar unit of claim 6, wherein, The first terminal includes:

8. The busbar unit of claim 6, wherein, a first body; and 9. The busbar unit of claim 2, wherein, a first terminal portion extending from the first body and exposed from an upper surface of the holder, wherein the second terminal includes: a second body; and a second terminal portion extending from the second body and exposed from the upper surface of the holder, wherein the third terminal includes: a third body; and a third terminal portion extending from the third body and exposed from the upper surface of the holder, wherein the fourth terminal includes: a fourth body; and a fourth terminal portion extending from the fourth body and exposed from the upper surface of the holder. The spacer has a through hole through which the first terminal portion and the second terminal portion pass. 11.The bus bar unit of claim 1, comprising:

10. The busbar unit of claim 9, wherein, a coil support unit provided on an upper portion of the holder and configured to support a coil of a stator. The coil support unit has a coil receiving groove that receives the coil. ​ 12. The busbar unit of claim 11, wherein, ​ 13. The busbar unit of claim 1, wherein, The second terminal is disposed to be spaced apart from the first terminal in a horizontal direction, the third terminal is stacked on an upper portion of the first terminal in a vertical direction, and the fourth terminal is stacked on an upper portion of the second terminal in the vertical direction.

Images