busbar unit

Abstract

This disclosure provides a bus unit that improves the temperature detection accuracy of a temperature sensor on a bus. The bus unit (10) includes a bus (13), a temperature sensor (14), and a covering member (71) made of insulating resin covering the bus (13) and the temperature sensor (14). The temperature sensor (14) has a thermistor element (41) and a housing (51) for housing the thermistor element (41). The bus (13) has a sensor holding portion (22) for holding the temperature sensor (14). The sensor holding portion (22) has: a first support portion (31) having a first contact surface (31a); a second support portion (32) having a second contact surface (32a) opposite to the first contact surface (31a); and a connecting portion connecting one end of the first support portion (31) and the second support portion (32) to each other. The sensor holding part (22) holds the temperature sensor (14) by clamping the housing (51) with the first contact surface (31a) and the second contact surface (32a). The covering part (71) covers the outside of the sensor holding part (22) and the housing (51).

Description

Technical Field

[0001] This disclosure relates to busbar units. Background Technology

[0002] A rotary electric motor exists that includes: a stator having stator coils; and a busbar unit having busbars electrically connected to the stator coils for supplying power to the stator coils. In such a rotary electric motor, the stator coils heat up due to the energization. Furthermore, if the temperature of the stator coils rises, malfunctions may occur in various parts of the rotary electric motor. Therefore, in order to monitor the temperature of the stator coils, the busbar unit is equipped with a temperature sensor that detects the temperature of the busbars electrically connected to the stator coils.

[0003] In the bus unit described in Patent Document 1, one bus has a U-shaped section bent into a U-shape. The temperature sensor has: a main body that houses a thermistor element disposed between a pair of legs of the U-shaped section; and an arm that extends from the main body in a manner that embraces the legs of the U-shaped section. The temperature sensor can be attached to and detached from the U-shaped section by elastically deforming the arm.

[0004] Existing technical documents

[0005] Patent Literature

[0006] Patent Document 1: Japanese Patent Application Publication No. 2018-61389 Summary of the Invention

[0007] The problem that the invention aims to solve

[0008] However, as described in Patent Document 1, if the temperature sensor can be attached and detached from the busbar, it is difficult to securely fix the main body of the thermistor element that houses the temperature of the busbar to the busbar. Therefore, it may be difficult to accurately detect the temperature of the busbar using the temperature sensor.

[0009] The purpose of this disclosure is to provide a bus unit that can improve the accuracy of temperature sensor detection of the bus.

[0010] Methods for solving problems

[0011] The disclosed busbar unit is electrically connected to the stator coils of the stator and includes: a busbar; a temperature sensor that detects the temperature of the busbar; and a covering member made of insulating resin that covers the busbar and the temperature sensor. The temperature sensor has a thermistor element and a housing for housing the thermistor element. The busbar has a sensor holding portion for holding the temperature sensor. The sensor holding portion has: a first support portion having a first contact surface that contacts the housing; a second support portion having a second contact surface that faces the first contact surface and contacts the housing; and a connecting portion that connects one end of the first support portion and the second support portion to each other. The sensor holding portion holds the temperature sensor by clamping the housing with the first contact surface and the second contact surface. The covering member covers the sensor holding portion and the outer side of the housing.

[0012] The effects of the invention

[0013] According to the bus unit disclosed herein, the accuracy of temperature sensor detection of bus temperature can be improved. Attached Figure Description

[0014] Figure 1 This is a schematic diagram of a busbar unit in one embodiment.

[0015] Figure 2 This is an exploded perspective view of the busbar and temperature sensor in one embodiment.

[0016] Figure 3 This is a side view of the sensor holding part and the temperature sensor in one embodiment.

[0017] Figure 4 This is a cross-sectional view showing a portion of a busbar unit in one embodiment.

[0018] Figure 5 This is a perspective view showing a portion of a busbar unit in one embodiment. Detailed Implementation

[0019] [Description of embodiments of this disclosure]

[0020] First, embodiments of the present disclosure will be described and explained in parallel.

[0021] The busbar unit of this disclosure is configured as follows:

[0022] (1) An electrical connection to a stator coil of a stator, comprising: a busbar; a temperature sensor that detects the temperature of the busbar; and a covering member made of insulating resin that covers the busbar and the temperature sensor, the temperature sensor having a thermistor element and a housing for housing the thermistor element, the busbar having a sensor holding portion for holding the temperature sensor, the sensor holding portion having: a first support portion having a first contact surface that contacts the housing; a second support portion having a second contact surface that faces the first contact surface and contacts the housing; and a connecting portion that connects one end of the first support portion and the second support portion to each other, and the sensor holding portion holding the temperature sensor by clamping the housing with the first contact surface and the second contact surface, the covering member covering the sensor holding portion and the outer side of the housing.

[0023] According to the above method, the sensor holding part clamps the housing with a first contact surface and a second contact surface. Therefore, the first contact surface and the second contact surface, which are in contact with the housing, are easily and tightly fixed to the housing on both sides of the clamping direction in which the housing is clamped. As a result, the temperature of the busbar is easily transferred to the thermistor element through the housing. Consequently, the temperature sensor can improve the detection accuracy of the busbar temperature.

[0024] (2) Preferably, the housing has an abutting surface that abuts against the sensor holding part, and the abutting surface is opposite to the sensor holding part in a direction orthogonal to the clamping direction of the first contact surface and the second contact surface that clamps the housing.

[0025] According to the above method, the temperature sensor is positioned relative to the sensor holding part in a direction orthogonal to the clamping direction by abutting the contact surface against the sensor holding part.

[0026] (3) Preferably, at least a portion of the housing and the sensor holding portion are integrated with the covering component in a state of being covered by the covering component, the covering component having: a first exposure hole that exposes a portion of the surface of the first support portion opposite to the first contact surface to the outside; and a second exposure hole that exposes a portion of the surface of the second support portion opposite to the second contact surface to the outside, the first exposure hole and the second exposure hole extending along the clamping direction of the first contact surface and the second contact surface clamping the housing.

[0027] According to the above method, a pin for forming a first exposed hole and a pin for forming a second exposed hole are provided in the mold for forming the covering component. The pin for forming the first exposed hole extends inside the mold along the clamping direction and abuts against the surface of the first support portion opposite to the first contact surface. The pin for forming the second exposed hole extends inside the mold along the clamping direction and abuts against the surface of the second support portion opposite to the second contact surface. Therefore, the covering component is formed in a state in which the sensor holding portion is clamped from both sides of the clamping direction by the aforementioned pins. As a result, when molten resin material for forming the covering component is filled into the mold, separation of the first support portion and the second support portion can be prevented by the aforementioned pins. Therefore, during the formation of the covering component, the reduction of the tight fixation between the housing and the sensor holding portion can be prevented.

[0028] (4) Preferably, the outer shell has an anti-detachment protrusion that protrudes from the outer surface of the outer shell to the outer side of the outer shell, and the anti-detachment protrusion is integrated with the covering component in a state of being covered by the covering component.

[0029] According to the above method, since the anti-detachment protrusion is embedded in the covering component, relative movement of the anti-detachment protrusion relative to the covering component is suppressed. Therefore, it is possible to suppress the temperature sensor from falling off the busbar not only by the clamping of the housing by the sensor holding part, but also by the physical engagement of the anti-detachment protrusion with the covering component.

[0030] (5) Preferably, the housing is configured such that: one of the two ends in the clamping direction of the housing has an abutting surface that abuts against the sensor holding part, and the other end in the clamping direction of the housing has the anti-detachment protrusion; the abutting surface is opposite to the sensor holding part in a direction orthogonal to the clamping direction; the anti-detachment protrusion has an opposing surface that is opposite to the sensor holding part; the direction in which the opposing surface is opposite to the sensor holding part is the same as the opposing direction in which the abutting surface is opposite to the sensor holding part; and the positions of the abutting surface and the opposing surface are offset in the opposing direction.

[0031] According to the above method, since the abutting surface and the opposing surface are misaligned in the opposing direction, when installing the housing into the sensor holding part, it is possible to suppress the temperature sensor from being installed in an irregular posture that is reversed from the regular mounting posture relative to the sensor holding part.

[0032] [Details of the embodiments disclosed herein]

[0033] Specific examples of the busbar units of this disclosure will be described with reference to the accompanying drawings. Furthermore, the invention is not limited to these examples, but is defined by the claims, and is intended to include all modifications equivalent to the claims and within the scope of the claims.

[0034] The following describes one embodiment of the busbar unit. Note that in the accompanying drawings, some components are shown enlarged for ease of understanding. Furthermore, there are instances where the size ratios of the components differ from the actual ratios or from the ratios in other drawings.

[0035] Figure 1 The bus unit 10 shown in this embodiment is provided in a rotary electric motor used, such as an electric motor-generator set in a hybrid vehicle or electric vehicle. The rotary electric motor has an annular stator core (not shown). Stator coils (not shown) are wound around the stator core. Furthermore, the bus unit 10 is disposed at one end of the stator core along its axial direction.

[0036] (Composition of busbar unit 10)

[0037] The bus unit 10 includes a bus 13 for electrical connection of the stator coil and a temperature sensor 14 for detecting the temperature of the bus 13.

[0038] (Composition of busbar 13)

[0039] In this embodiment, busbar 13 serves as the neutral point of the stator coil. The ends of the stator coil are electrically connected to busbar 13 by welding. Thus, busbar unit 10 is electrically connected to the stator coil.

[0040] Busbar 13 is formed of a conductive metal plate. For example, copper or copper alloys with excellent conductivity can be used as the material for busbar 13.

[0041] The busbar 13 is generally arc-shaped. The busbar 13 has a sensor holding part 22 and a strip-shaped busbar body 21, wherein the sensor holding part 22 is integrally provided at one end of the long side of the busbar body 21. That is, the busbar 13 has a sensor holding part 22 at one end in the long side direction.

[0042] The busbar body 21 is formed such that, when viewed from the thickness direction, it is a strip extending along an arc. Furthermore, the busbar body 21 can be formed such that its width in the short side direction is not constant, or it can be a stepped shape. Moreover, in the figure, the long side direction of the busbar body 21 is shown as arrow C, the short side direction as arrow R, and the thickness direction as arrow A.

[0043] like Figure 2 as well as Figure 3 As shown, the sensor holding part 22 is formed by bending a portion of the busbar 13 into a U-shape. The sensor holding part 22 has a pair of first support parts 31 and second support parts 32, and a connecting part 33 that connects one end of the first support part 31 and the second support part 32 to each other.

[0044] The first support portion 31 and the second support portion 32 are square flat plates. The second support portion 32 extends from one end of the busbar body 21 along its long side. Furthermore, the thickness direction of the second support portion 32 is along the thickness direction of the busbar body 21. The first support portion 31 extends away from the second support portion 32 in the thickness direction of the second support portion 32. Furthermore, the first support portion 31 and the second support portion 32 are opposite each other along the thickness direction of the second support portion 32. Moreover, the thickness direction of the first support portion 31 is along the thickness direction of the second support portion 32. Additionally, the first support portion 31 extends along the short side of the busbar body 21 when viewed from its thickness direction.

[0045] The connecting portion 33 is plate-shaped, extending along the thickness direction of the busbar body 21, i.e., the thickness direction of the second support portion 32. Furthermore, the thickness direction of the connecting portion 33 is along the short side direction of the busbar body 21. The connecting portion 33 connects one end of the first support portion 31 in the short side direction of the busbar body 21 to one end of the second support portion 32 in the short side direction of the busbar body 21. Therefore, the sensor holding portion 22 of this embodiment is formed in a U-shape with an opening on one side in the short side direction of the busbar body 21 when viewed from the long side direction.

[0046] The first support portion 31 has a first contact surface 31a. The first contact surface 31a is a side surface of the first support portion 31 that faces the second support portion 32. The second support portion 32 has a second contact surface 32a. The second contact surface 32a is a side surface of the second support portion 32 that faces the first support portion 31, and is the surface of the second support portion 32 that faces the first contact surface 31a in the plate thickness direction.

[0047] The sensor holding part 22 can be elastically deformed so that the interval between the first support part 31 and the second support part 32 in the thickness direction of the second support part 32 changes, that is, the distance between the first contact surface 31a and the second contact surface 32a in the thickness direction of the second support part 32 changes.

[0048] (Composition of temperature sensor 14)

[0049] like Figure 2 as well as Figure 4As shown, the temperature sensor 14 has a thermistor element 41 and a housing 51 for housing the thermistor element 41. One end of a pair of wires 42 is electrically connected to the thermistor element 41, and a connector portion 43 is provided at the other end of the wires 42. The connector portion 43 is only located at... Figure 1 As shown in the image.

[0050] The outer casing 51 is formed of an insulating resin material, such as polyphenylene sulfide resin (PPS). The resin material of the outer casing 51 may contain fillers or other additives. The outer casing 51 is rectangular parallelepiped in shape. Here, one outer surface extending along the long side of the outer periphery of the outer casing 51 is designated as the first outer surface 52a. Figure 2 as well as Figure 4 In this embodiment, the first outer surface 52a corresponds to the upper surface of the outer casing 51. Furthermore, the outer surface located behind the first outer surface 52a among the outer surfaces of the outer peripheral surface of the outer casing 51 extending along its long side is designated as the second outer surface 52b. The second outer surface 52b corresponds to the lower surface of the outer casing 51. In this embodiment, the second outer surface 52b is parallel to the first outer surface 52a. Additionally, one end of the outer casing 51 along its long side is designated as the first end 53a, and the other end along its long side is designated as the second end 53b.

[0051] The housing 51 has a component storage portion 54, which is recessed along the long side of the housing 51 from the second end 53b toward the first end 53a. A thermistor element 41 is disposed in the component storage portion 54. A pair of wires 42 are pulled out from the opening of the component storage portion 54 to the outside of the housing 51. Furthermore, the thermistor element 41 is sealed inside the housing 51 by a sealing resin 61 filled in the component storage portion 54. The sealing resin 61 is formed of an insulating resin material, which may contain fillers or other additives.

[0052] A stepped portion 55 is provided at the end of the first outer surface 52a on the first end 53a side. That is, the stepped portion 55 is provided at the end of the first outer surface 52a on the bottom side of the component housing 54. The stepped portion 55 is formed in such a way that the thickness of the housing 51 in the direction perpendicular to the first outer surface 52a is reduced. The housing 51 has a contact surface 56 that is planar and perpendicular to the first outer surface 52a by having this stepped portion 55. In addition, in the housing 51, the portion where the stepped portion 55 is formed, that is, the portion closer to the first end 53a side than the contact surface 56, becomes an insertion portion 57 that is inserted into the sensor holding portion 22.

[0053] like Figure 3As shown, the thickness T1 of the insertion portion 57 in the direction perpendicular to the first outer surface 52a is formed to be greater than the distance between the first support portion 31 and the second support portion 32, i.e., the distance D1 between the first contact surface 31a and the second contact surface 32a, before the temperature sensor 14 is installed in the sensor holding portion 22. Furthermore, Figure 3 The sensor holding part 22 and the temperature sensor 14 shown are from Figure 2 The side view of the sensor holding part 22 and the temperature sensor 14 is viewed in the direction of arrow β.

[0054] like Figure 2 as well as Figure 4 As shown, the outer casing 51 has an anti-detachment protrusion 58 that protrudes outward from the second outer surface 52b. Viewed from a direction perpendicular to the second outer surface 52b, the anti-detachment protrusion 58 is a raised strip extending along the short side of the outer casing 51 on the second outer surface 52b. Furthermore, in a cross-section perpendicular to the second outer surface 52b and parallel to the long side of the outer casing 51, the anti-detachment protrusion 58 protrudes from the second outer surface 52b in a rectangular shape.

[0055] Of the two side surfaces of the anti-detachment protrusion 58 along the long side of the outer casing 51, the side surface on the first end 53a side is the opposing surface 59. The opposing surface 59 faces the same direction as the abutment surface 56. The opposing surface 59 is configured to be parallel to the abutment surface 56 and perpendicular to the second outer side surface 52b. The abutment surface 56 and the opposing surface 59 are offset in position along the long side of the outer casing 51. In this embodiment, the opposing surface 59 is located on the second end 53b side in the long side of the outer casing 51 than the abutment surface 56.

[0056] like Figure 2 , Figure 4 as well as Figure 5 As shown, the temperature sensor 14 is held by the sensor holding part 22. When the temperature sensor 14 is installed on the busbar 13, the insertion part 57 is inserted between the first support part 31 and the second support part 32 along the direction of extension of the busbar body 21, that is, along the long side direction of the busbar body 21. Furthermore, by moving the housing 51 relative to the sensor holding part 22 along the long side direction of the housing 51, the temperature sensor 14 inserts the insertion part 57 between the first support part 31 and the second support part 32. Figure 2Arrow α indicates the insertion direction of the temperature sensor 14 relative to the sensor holding part 22, i.e., the insertion direction of the housing 51. At this time, the thickness T1 of the insertion part 57 is greater than the distance D1 between the first contact surface 31a and the second contact surface 32a in the sensor holding part 22 before the housing 51 is inserted. Therefore, the insertion part 57 is pressed between the first support part 31 and the second support part 32. Thus, the first contact surface 31a contacts the insertion part 57 in a state where it is pressed against the surface of the insertion part 57, and the second contact surface 32a contacts the insertion part 57 in a state where it is pressed against the surface of the insertion part 57. Furthermore, the insertion part 57, i.e., the housing 51, is clamped by the first support part 31 and the second support part 32. That is, the sensor holding part 22 clamps the housing 51 with the first contact surface 31a and the second contact surface 32a, thereby holding the temperature sensor 14. Furthermore, the temperature sensor 14 is inserted into the sensor holding portion 22 along the long side of the busbar body 21 before the abutment surface 56 abuts against the first support portion 31. By abutting against the first support portion 31 with the abutment surface 56, the housing 51 is positioned relative to the sensor holding portion 22 in the insertion direction.

[0057] like Figure 4 as well as Figure 5 As shown, with the temperature sensor 14 held in the sensor holding part 22, the abutment surface 56 faces and abuts against the sensor holding part 22 in a direction orthogonal to the clamping direction X1 of the first contact surface 31a and the second contact surface 32a that clamps the housing 51. In this embodiment, the direction orthogonal to the clamping direction X1 is the same as the insertion direction of the housing 51 relative to the sensor holding part 22, which is the long side direction of the busbar body 21. That is, the abutment surface 56 faces and abuts against the first support part 31 in the long side direction of the busbar body 21.

[0058] Furthermore, in this state, the anti-detachment protrusion 58 is provided at one of the two ends of the housing 51 in the clamping direction X1, opposite to the end where the abutment surface 56 is provided. That is, the housing 51 is formed such that one end of the housing 51 in the clamping direction X1 has an abutment surface 56, and the other end of the housing 51 in the clamping direction X1 has an anti-detachment protrusion 58. Moreover, the opposing surface 59 of the anti-detachment protrusion 58 faces the sensor holding portion 22. The direction in which the opposing surface 59 faces the sensor holding portion 22 is the same as the opposing direction X2 in which the abutment surface 56 faces the sensor holding portion 22. Furthermore, in this embodiment, the opposing direction X2 is consistent with the long side direction of the housing 51, therefore, the positions of the abutment surface 56 and the opposing surface 59 are offset in the opposing direction X2. Furthermore, in this embodiment, the opposing direction X2 is the long side direction of the busbar body 21. Therefore, the opposing surface 59 is opposite to the second support portion 32 in the long side direction of the busbar body 21. Moreover, in this embodiment, the opposing surface 59 abuts against the second support portion 32 from the long side direction of the busbar body 21.

[0059] like Figure 1 As shown, in this embodiment, when viewed from the thickness direction of the busbar body 21, the long side of the outer casing 51 is along the long side of the busbar body 21 and perpendicular to the short side of the busbar body 21. However, when viewed from the thickness direction of the busbar body 21, the long side of the outer casing 51 does not necessarily have to be perpendicular to the short side of the busbar body 21; it can be any direction.

[0060] (Composition of the covering component 71)

[0061] like Figure 4 as well as Figure 5 As shown, the bus unit 10 has a covering member 71 made of insulating resin that covers the sensor holding part 22 and the outer side of the housing 51. The term "insulating resin" broadly includes resins other than conductive resins, such as polyamide resins. The insulating resin may contain additives. In this embodiment, a polyamide resin containing fillers or the like as additives is used as the resin material forming the covering member 71.

[0062] A portion of the housing 51 and the sensor holding portion 22 are integrated with the covering member 71 in a state covered by the covering member 71. Specifically, the sensor holding portion 22 is entirely disposed within the covering member 71 in a manner that it is embedded inside the covering member 71. The covering member 71 is tightly fixed to the outer surface of the sensor holding portion 22, covering the outer surface. Furthermore, the portion from the first end 53a of the housing 51 to a predetermined position between the anti-detachment protrusion 58 and the second end 53b is disposed within the covering member 71 in a manner that it is embedded inside the covering member 71. That is, the covering member 71 covers the area of ​​the housing 51 from the first end 53a to the predetermined position between the anti-detachment protrusion 58 and the second end 53b. The covering member 71 is tightly fixed to the outer surface of this area of ​​the housing 51, covering the outer surface. Therefore, the covering member 71 is tightly fixed to the outer surface of the anti-detachment protrusion 58, covering the outer surface. Furthermore, the anti-detachment protrusion 58 is integrated with the covering member 71 in such a state that the outer surface of the anti-detachment protrusion 58 is covered by the covering member 71. In addition, the second end 53b protrudes from the covering member 71. The busbar 13, the temperature sensor 14, and the covering member 71 are formed into one piece by insert molding.

[0063] The covering member 71 has a first exposure hole 72 and a second exposure hole 73 on both sides of the sensor holding portion 22 in the clamping direction X1. The first exposure hole 72 exposes a portion of the surface of the first support portion 31 opposite to the first contact surface 31a to the outside. The second exposure hole 73 exposes a portion of the surface of the second support portion 32 opposite to the second contact surface 32a to the outside. The first exposure hole 72 and the second exposure hole 73 extend along the clamping direction X1.

[0064] The first exposed hole 72 and the second exposed hole 73 are formed simultaneously during the forming of the covering member 71 by insert molding. During the forming of the covering member 71, a sensor holding portion 22, which holds the housing 51, is disposed inside a mold (not shown) used to form the covering member 71. A first pin (not shown) is provided on the inner surface of the mold, extending along the clamping direction X1 and abutting against the surface of the first support portion 31 opposite to the first contact surface 31a. Furthermore, a second pin (not shown) is provided on the inner surface of the mold, extending along the clamping direction X1 and abutting against the surface of the second support portion 32 opposite to the second contact surface 32a. With the sensor holding portion 22 clamped from both sides of the clamping direction X1 by the first and second pins, molten resin material for forming the covering member 71 is filled into the mold. Then, the resin material solidifies to form the covering member 71. When the covering component 71 is removed from the mold, the first pin and the second pin are also pulled out of the covering component 71. Therefore, in the covering component 71, a first exposure hole 72 is formed at the location of the first pin, and a second exposure hole 73 is formed at the location of the second pin.

[0065] The function and effects of this implementation method are explained.

[0066] (1) A busbar unit 10 electrically connected to the stator coils of the stator includes: a busbar 13; a temperature sensor 14 that detects the temperature of the busbar 13; and a covering member 71 made of insulating resin that covers the busbar 13 and the temperature sensor 14. The temperature sensor 14 has a thermistor element 41 and a housing 51 that houses the thermistor element 41. The busbar 13 has a sensor holding portion 22 that holds the temperature sensor 14. The sensor holding portion 22 has: a first support portion 31 having a first contact surface 31a that contacts the housing 51; a second support portion 32 having a second contact surface 32a that faces the first contact surface 31a and contacts the housing 51; and a connecting portion 33 that connects one end of the first support portion 31 and the second support portion 32 to each other. The sensor holding portion 22 holds the temperature sensor 14 by clamping the housing 51 with the first contact surface 31a and the second contact surface 32a. The covering component 71 covers the sensor holding part 22 and the outer side of the housing 51.

[0067] According to the above method, the sensor holding part 22 clamps the housing 51 with the first contact surface 31a and the second contact surface 32a. In this embodiment, the insertion part 57 of the housing 51 is pressed between the first support part 31 and the second support part 32, thereby pressing the first contact surface 31a and the second contact surface 32a against the insertion part 57. Therefore, the first contact surface 31a and the second contact surface 32a in contact with the housing 51 are tightly fixed to the housing 51 on both sides of the clamping direction X1. As a result, the temperature of the busbar 13 can be easily transferred to the thermistor element 41 through the housing 51. As a result, the detection accuracy of the temperature sensor 14 of the busbar 13 can be improved.

[0068] In addition, the sensor holding part 22 and the housing 51 are covered by the covering part 71, so the temperature sensor 14 is prevented from falling off the sensor holding part 22 by the covering part 71.

[0069] (2) The housing 51 has an abutting surface 56 that abuts against the sensor holding part 22. The abutting surface 56 is opposite to the sensor holding part 22 in a direction orthogonal to the clamping direction X1 of the first contact surface 31a and the second contact surface 32a that clamps the housing 51.

[0070] According to the above method, the abutment surface 56 abuts against the sensor holding part 22, thereby positioning the temperature sensor 14 relative to the sensor holding part 22 in a direction orthogonal to the clamping direction X1. In this embodiment, the abutment surface 56 abuts against the first support part 31 from the long side direction of the busbar body 21, thereby positioning the temperature sensor 14 relative to the sensor holding part 22 in the long side direction of the busbar body 21, that is, positioning the housing 51 relative to the sensor holding part 22 in the long side direction of the housing 51. Therefore, it is easy to install the temperature sensor 14 into the sensor holding part 22.

[0071] (3) A portion of the housing 51 and the sensor holding portion 22 are integrated with the covering member 71 in a state of being covered by the covering member 71. The covering member 71 has a first exposure hole 72 that exposes a portion of the surface of the first support portion 31 opposite to the first contact surface 31a to the outside, and a second exposure hole 73 that exposes a portion of the surface of the second support portion 32 opposite to the second contact surface 32a to the outside. The first exposure hole 72 and the second exposure hole 73 extend along the clamping direction X1 of the first contact surface 31a and the second contact surface 32a clamping the housing 51.

[0072] According to the above method, the mold for forming the covering member 71 is provided with a first pin for forming the first exposed hole 72 and a second pin for forming the second exposed hole 73. The first pin extends inside the mold along the clamping direction X1 and abuts against the surface of the first support portion 31 opposite to the first contact surface 31a. The second pin extends inside the mold along the clamping direction X1 and abuts against the surface of the second support portion 32 opposite to the second contact surface 32a. Therefore, the covering member 71 is formed in a state in which the sensor holding portion 22 is clamped from both sides of the clamping direction X1 by the first pin and the second pin. As a result, when molten resin material for forming the covering member 71 is filled into the mold, separation of the first support portion 31 and the second support portion 32 can be prevented by the first pin and the second pin. Therefore, when forming the covering member 71, the reduction of the tight fixation between the outer shell 51 and the sensor holding portion 22 can be prevented.

[0073] Furthermore, since the covering component 71 is integrated with the housing 51 and the sensor holding part 22 by covering a portion of the housing 51, the temperature sensor 14 cannot be attached or detached relative to the busbar 13. Therefore, compared to the case where the temperature sensor can be attached or detached relative to the busbar, the temperature sensor 14 can be securely fixed to the busbar 13.

[0074] (4) The outer casing 51 has an anti-detachment protrusion 58 that protrudes from the second outer side 52b toward the outside of the outer casing 51. The anti-detachment protrusion 58 is integrated with the covering member 71 in a state of being covered by the covering member 71.

[0075] According to the above method, since the anti-detachment protrusion 58 is embedded in the covering member 71, the anti-detachment protrusion 58 is suppressed from moving relative to the covering member 71. Therefore, not only can the sensor holding part 22 hold the housing 51, but the physical engagement between the anti-detachment protrusion 58 and the covering member 71 can also suppress the temperature sensor 14 from falling off the busbar 13.

[0076] (5) The housing 51 is formed such that one of its two ends in the clamping direction X1 has an abutment surface 56 that abuts against the sensor holding portion 22, and the other end in the clamping direction X1 has an anti-detachment protrusion 58. The abutment surface 56 faces the sensor holding portion 22 in a direction orthogonal to the clamping direction X1. The anti-detachment protrusion 58 has an opposing surface 59 that faces the sensor holding portion 22. The direction in which the opposing surface 59 faces the sensor holding portion 22 is the same as the opposing direction X2 in which the abutment surface 56 faces the sensor holding portion 22. The abutment surface 56 and the opposing surface 59 are offset in the opposing direction X2.

[0077] According to the above method, since the abutting surface 56 and the opposing surface 59 are misaligned in the opposing direction X2, when the housing 51 is installed on the sensor holding part 22, it is possible to prevent the temperature sensor 14 from being installed on the sensor holding part 22 in an irregular posture that is reversed from the regular mounting posture relative to the sensor holding part 22.

[0078] This embodiment can be implemented by modification as follows. This embodiment and the following variations can be combined and implemented within the scope that does not contradict the technical content.

[0079] • In the above embodiment, the opposing surface 59 abuts against the second support portion 32 of the sensor holding portion 22. However, the opposing surface 59 does not necessarily have to abut against the sensor holding portion 22. In this case, as long as the abutting surface 56 and the opposing surface 59 are misaligned in the opposing direction X2, the same effect as in embodiment (5) above can be obtained.

[0080] In the above embodiment, the opposing surface 59 is provided on the side of the anti-detachment protrusion 58. However, the opposing surface 59 can be formed in the housing 51 by providing a step portion 55 on the second outer side 52b. In addition, the housing 51 does not necessarily have to have the opposing surface 59.

[0081] In the above embodiment, the anti-detachment protrusion 58 is provided on the second outer surface 52b. However, the anti-detachment protrusion 58 may be provided on the first outer surface 52a, or on any outer surface other than the first outer surface 52a and the second outer surface 52b that constitute the outer peripheral surface of the housing 51. In addition, the housing 51 is not required to have the anti-detachment protrusion 58.

[0082] • The covering member 71 may have only one of the first exposure hole 72 and the second exposure hole 73. Alternatively, the covering member 71 may not have the first exposure hole 72 and the second exposure hole 73.

[0083] In the above embodiment, an abutment surface 56 is formed on the outer casing 51 by providing a stepped portion 55. However, an anti-detachment protrusion 58 may be provided on the first outer surface 52a, and the side of the first end 53a of the anti-detachment protrusion 58 on the two sides in the long side direction of the outer casing 51 may be used as the abutment surface 56. In addition, the outer casing 51 is not required to have an abutment surface 56.

[0084] In the above embodiment, the insertion part 57 is inserted into the sensor holding part 22 along the long side direction of the outer casing 51 and along the long side direction of the busbar body 21. However, the insertion direction of the insertion part 57 into the sensor holding part 22 is not limited to this. For example, viewed from the thickness direction of the busbar body 21, the insertion part 57 can be inserted between the first support part 31 and the second support part 32 along the short side direction of the outer casing 51 and along the short side direction of the busbar body 21.

[0085] In the above embodiment, when viewed from the long side direction of the busbar body 21, the sensor holding portion 22 is U-shaped with an opening on one side of the short side direction of the busbar body 21. However, the sensor holding portion 22 only needs to include a first support portion 31 having a first contact surface 31a, a second support portion 32 having a second contact surface 32a opposite to the first contact surface 31a, and a connecting portion 33 connecting one end of the first support portion 31 and the second support portion 32 to each other; its shape is not limited to the shape of the above embodiment. For example, the sensor holding portion 22 may include a connecting portion 33 with an arc shape when viewed from the long side direction of the busbar body 21. In addition, for example, when viewed from the short side direction of the busbar body 21, the sensor holding portion 22 may be U-shaped with an opening on one side of the long side direction of the busbar body 21.

[0086] The shape of the busbar body 21 is not limited to the shape described in the above embodiment. For example, the busbar body may be a strip extending in a straight line.

[0087] In the above embodiment, the busbar 13 has a sensor holding portion 22 at one end in the long side direction. However, the location of the sensor holding portion 22 in the busbar 13 is not limited to this. For example, the busbar 13 may have a sensor holding portion 22 at the center in the long side direction.

[0088] In the above embodiments, examples of materials for the busbar 13 include copper and copper alloys. However, the material of the busbar 13 can be any metallic material, and is not limited to this. For example, the busbar 13 can be formed of aluminum or an aluminum alloy.

[0089] • Busbar 13 does not necessarily have to be the busbar that serves as the neutral point of the stator coil. Busbar 13 can be any busbar provided in busbar unit 10 for supplying power to the stator coil.

[0090] In the above embodiment, the covering component 71 is integrally formed with the sensor holding portion 22 and the housing 51 by insert molding. However, the covering component 71 can be any component formed of insulating resin that covers the outer side of the sensor holding portion 22 and the housing 51, and does not necessarily have to be formed by insert molding. For example, the covering component 71 can be a cover that is separately formed from the sensor holding portion 22 and the housing 51 and covers the sensor holding portion 22 and the housing 51 after the sensor holding portion 22 is inserted into the housing 51. Alternatively, for example, the covering component 71 can be formed of insulating resin applied to the sensor holding portion 22 and the housing 51.

[0091] • Busbar unit 10 can be configured to detect the temperature of the neutral point of the three-phase coils of a three-phase AC rotating motor. For example, busbar 13 can be configured to be connected to the neutral line of the three-phase coils of the three-phase AC rotating motor, or it can be configured as the neutral point itself.

[0092] ·like Figure 4 As shown, the sensor holding part 22 in the embodiment can be configured as a clamp or U-shaped clamp that holds the temperature sensor 14 at a position that is the same as or corresponds to the thermistor element 41.

[0093] ·like Figure 2 As shown, busbar 13 can have an end face or a first end face that intersects or is orthogonal to the long side direction (arrow C) of busbar 13. The first support portion 31 of sensor holding portion 22 can have a side end face that intersects or is orthogonal to the long side direction (arrow C) of busbar 13. This side end face of the first support portion 31 is sometimes referred to as the second end face of busbar 13. Figure 4 As shown, the first and second end faces of the busbar 13 may be offset in the long side direction (arrow C) and / or the thickness direction (arrow A) of the busbar 13. The first and second end faces of the busbar 13 can respectively contact the abutment surface 56 and the opposing surface 59 of the housing 51. The first and second end faces of the busbar 13, the abutment surface 56 and the opposing surface 59 of the housing 51 are an example of a stop portion that positions the housing 51 relative to the busbar 13.

[0094] • In some practical examples, such as Figure 4 As shown, on the outside of the housing 51, the busbar 13 (second contact surface 32a) can directly contact the outer surface of the housing 51, forming a metal-to-plastic planar interface.

[0095] • In some practical examples, such as Figure 4 As shown, on the inner side of the housing 51, the inner surface of the housing 51 can directly contact the outer surface of the thermistor element 41, forming a resin-resin contact surface or a resin-resin flat interface (aplastic-to-plastic planar interface).

[0096] • In some practical examples, such as Figure 4 As shown, the wall thickness of the outer casing 51 in the position sandwiched between the second contact surface 32a of the busbar 13 and the thermistor element 41 can be equal to the shortest distance between the second contact surface 32a of the busbar 13 and the outer surface of the thermistor element 41.

[0097] • In some practical examples, such as Figure 4As shown, the wall thickness of the outer casing 51 in the position sandwiched between the first support portion 31 of the busbar 13 and the thermistor element 41 can be equal to the shortest distance between the first support portion 31 of the busbar 13 and the outer surface of the thermistor element 41.

[0098] • In some practical examples, such as Figure 4 , 5 As shown, the end of the busbar 13 in the long side direction (arrow C) and the sensor holding part 22 can be covered by the covering member 71, and the end of the busbar 13 in the long side direction (arrow C) and the sensor holding part 22 do not need to protrude from the covering member 71.

[0099] • In some practical examples, such as Figure 4 , 5 As shown, the temperature sensor 14 may have a first length portion embedded in the cover member 71 and a second length portion protruding from the cover member 71 but not embedded in it. For example, the thermistor element 41 may be entirely contained within the first length portion of the temperature sensor 14. The stepped portion 55 and the anti-detachment protrusion 58 of the housing 51 may be included in the first length portion of the temperature sensor 14, embedded in the cover member 71 without being exposed.

[0100] This disclosure includes the following embodiments. Reference numerals are used to illustrate some components of the illustrative embodiments for the purpose of aiding understanding, but are not intended to limit the scope. In the following embodiments, some of the described items may be omitted, and some selections or extractions of the described items may be combined.

[0101] [Note 1] Preferably, the bus unit (10) according to one or more embodiments of this disclosure is configured to detect the temperature of the neutral point of the three-phase coils of a three-phase AC rotating motor. The bus unit (10) includes a temperature sensor (14), a bus (13), and an insulating resin coating (71).

[0102] The temperature sensor (14) has a thermistor element (41) and an insulating resin housing (51) for housing the thermistor element (41).

[0103] The busbar (13) is configured to be electrically connected to the neutral line of the neutral point of the three-phase coils of a three-phase AC rotating motor, or to be the neutral point itself. The busbar (13) has: a long side direction (C); a mounting surface (32a) configured to mount the temperature sensor (14) in the long side direction; and a clamp (22) that clamps the temperature sensor (14) on the mounting surface (32a) at a position corresponding to the thermistor element (41).

[0104] The insulating resin coating (71) is configured to cover a portion of the busbar (13) and a portion of the temperature sensor (14), and the clamp (22) is disposed on the portion of the busbar (13) covered by the insulating resin coating (71).

[0105] Explanation of reference numerals in the attached figures

[0106] 10 busbar units

[0107] 13 busbars

[0108] 14 Temperature Sensor

[0109] 21 Busbar Main Body

[0110] 22 Sensor holding section

[0111] 31 First Support Section

[0112] 31a First contact surface

[0113] 32 Second Support

[0114] 32a Second contact surface

[0115] 33 Connecting parts

[0116] 41 Thermistor element

[0117] 42 electrical wires

[0118] 43 Connector Section

[0119] 51. Outer shell

[0120] 52a First outer surface

[0121] 52b Second outer surface

[0122] 53a First end

[0123] 53b End 2

[0124] 54 Component Storage Section

[0125] 55 Steps

[0126] 56. Contact surface

[0127] 57 Insertion section

[0128] 58 Anti-falling convex part

[0129] 59 Opposite surfaces

[0130] 61 Sealing Resin

[0131] 71 Covered Components

[0132] 72 First exposed hole

[0133] 73 Second exposed hole

[0134] D1 Distance

[0135] T1 thickness

[0136] X1 Clamping direction

[0137] X2 Opposite Direction

Claims

1. A busbar unit electrically connected to the stator coils of a stator, comprising: busbar; A temperature sensor that detects the temperature of the busbar; and An insulating resin-coated component covers the busbar and the temperature sensor. The temperature sensor has a thermistor element and a housing for housing the thermistor element. The busbar has a sensor holding part for holding the temperature sensor. The sensor holding portion includes: a first support portion having a first contact surface that contacts the housing; a second support portion having a second contact surface facing the first contact surface and contacting the housing; and a connecting portion that connects one end of the first support portion and the second support portion to each other. The sensor holding portion holds the temperature sensor by clamping the housing with the first contact surface and the second contact surface. The covering component covers the sensor holding part and the outer side of the housing. At least a portion of the housing and the sensor holding portion are integrated with the covering component in a state where they are covered by the covering component. The covering component has: a first exposure hole that exposes a portion of the surface of the first support portion opposite to the first contact surface to the outside; and a second exposure hole that exposes a portion of the surface of the second support portion opposite to the second contact surface to the outside. The first exposed hole and the second exposed hole extend along the clamping direction of the first contact surface and the second contact surface clamping the housing.

2. The busbar unit according to claim 1, wherein, The housing has an abutting surface that abuts against the sensor holding part. The abutting surface is opposite the sensor holding part in a direction orthogonal to the clamping direction of the first contact surface and the second contact surface that clamps the housing.

3. The bus unit according to claim 1 or claim 2, wherein, The outer casing has an anti-detachment protrusion that protrudes from the outer surface of the outer casing towards the outer side of the outer casing. The anti-detachment protrusion is integrated with the covering component in a state where it is covered by the covering component.

4. The busbar unit according to claim 3, wherein, The housing is configured such that one end of the housing in the clamping direction has an abutment surface that abuts against the sensor holding portion, and the other end of the housing in the clamping direction has the anti-detachment protrusion. The contact surface is opposite the sensor holding part in a direction orthogonal to the clamping direction. The anti-detachment protrusion has a facing surface that is opposite to the sensor holding part. The direction in which the opposing surface faces the sensor holding part is the same as the direction in which the abutting surface faces the sensor holding part. The abutting surface and the opposing surface are offset in the opposing direction.

5. A busbar unit electrically connected to the stator coils of the stator, comprising: busbar; A temperature sensor that detects the temperature of the busbar; and An insulating resin-coated component covers the busbar and the temperature sensor. The temperature sensor has a thermistor element and a housing for housing the thermistor element. The busbar has a sensor holding part for holding the temperature sensor. The sensor holding portion includes: a first support portion having a first contact surface that contacts the housing; a second support portion having a second contact surface facing the first contact surface and contacting the housing; and a connecting portion that connects one end of the first support portion and the second support portion to each other. The sensor holding portion holds the temperature sensor by clamping the housing with the first contact surface and the second contact surface. The covering component covers the sensor holding part and the outer side of the housing. The outer casing has an anti-detachment protrusion that protrudes from the outer surface of the outer casing towards the outer side of the outer casing. The anti-detachment protrusion is integrated with the covering component in a state where it is covered by the covering component. The housing is configured such that one of its two ends in the clamping direction has an abutment surface that abuts against the sensor holding portion, and the other end in the clamping direction has the anti-detachment protrusion. The contact surface is opposite the sensor holding part in a direction orthogonal to the clamping direction. The anti-detachment protrusion has a facing surface that is opposite to the sensor holding part. The direction in which the opposing surface faces the sensor holding part is the same as the direction in which the abutting surface faces the sensor holding part. The abutting surface and the opposing surface are offset in the opposing direction.

Images