Method for manufacturing a connector receiving unit, connector receiving unit and electrical component

Abstract

The stator of one aspect of the present disclosure includes a connector molding portion having a base portion and a mounting portion, and a receiving-side terminal. A communication hole is formed in the connector molding portion, the communication hole having a first recess portion having an inner side opening that opens on an inner side of the housing and extending in an X direction in the base portion, and a second recess portion having a bottom surface opening that opens on a bottom surface of the mounting portion and extending in a Y direction in the base portion, the communication hole communicating the inside and outside of the housing through the first recess portion and the second recess portion. The first recess portion penetrates the base portion in the X direction through an outer side opening. A back cover portion that closes the outer side opening is provided.

Description

Technical Field

[0001] This disclosure relates to a method of manufacturing a connector receiving unit, a connector receiving unit, and an electrical component. Background Technology

[0002] A connector receiving portion is provided in an electrical component (e.g., a motor or pump) mounted in a vehicle or similar device. The connector receiving portion extends through the inside and outside of the housing of the electrical component. A connector extending from an external power source is mounted on the outside of the housing via the connector receiving portion. Thus, a control board located inside the housing is electrically connected to the external power source via the connector receiving portion.

[0003] The connector receiving part includes a molded body made of resin material or the like and terminals molded into the molded body. A communication hole is formed in the molded body to connect the inside and outside of the housing. According to this configuration, gas inside and outside the housing, and the pressure difference between them, enter and exit through the communication hole accordingly. As a result, the pressure difference between the inside and outside of the housing is alleviated.

[0004] As a method for forming the aforementioned connecting hole, Patent Document 1 discloses a method in which, during the formation of the molded body, injection molding is performed with the top ends of two rods joined together, and then the two rods are pulled out. According to this method, the portions formed from the two rods are connected via the joined portions of the rods. As a result, it is conceivable that the portions formed from the two rods can function as connecting holes.

[0005] Existing technical documents

[0006] Patent documents

[0007] Patent Document 1: Japanese Patent Application Publication No. 2001-128407 Summary of the Invention

[0008] The problem the invention aims to solve

[0009] However, the aforementioned prior art still has room for improvement in terms of the shape accuracy or manufacturing efficiency of the connecting holes, and the durability of the molding die (rod). Specifically, in the aforementioned prior art, the top ends of the rods need to be joined together, thus requiring high precision in the positioning of the rods. Since the rods extend in a cantilevered manner, misalignment or deformation may occur due to injection pressure during molding. If injection molding is performed with the top ends of the rods misaligned, the connecting holes will not form with the desired cross-sectional area, or the connecting holes may close midway. As a result, the yield rate may decrease.

[0010] This disclosure provides a method for manufacturing a connector receiving unit, a connector receiving unit, and an electrical component that can improve the shape accuracy or manufacturing efficiency of the connecting hole and the durability of the manufacturing apparatus.

[0011] Solution for solving the problem

[0012] To address the aforementioned issues, the present disclosure adopts the following solution.

[0013] (1) A method for manufacturing a connector receiving unit according to one aspect of the present disclosure is a method for manufacturing a connector receiving unit disposed in a housing housing containing electronic components and electrically connected to the external power source by a connector extending from an external power source through which the electronic components are mounted. The connector receiving unit comprises: a first molding portion integrally formed of resin material, having a base portion extending across the inside and outside of the housing, and a bottomed cylindrical mounting portion opening on the outside of the housing; and a terminal configured to penetrate the first molding portion, having a first end exposed inside the housing for connection with the electronic components, and a second end exposed inside the mounting portion for connection with the connector. A connecting hole is formed in the first molding portion, the connecting hole having: a first recess having a first opening opening on the inside of the housing and extending along a first direction in the base portion; and a second recess having a second opening opening on the bottom surface of the mounting portion and extending along a first direction in the base portion. The second direction extends in a direction intersecting the first direction. The connecting hole connects the inside and outside of the housing through the first recess and the second recess. The manufacturing method of the connector receiving unit includes a first molding step. The first molding step forms the first molded part by molding with resin material while the first pin forming the first recess, the second pin forming the second recess, and the terminal are placed in a molding mold. In the first molding step, the two ends of one of the first pins and the second pin are supported by the molding mold, and one end of the other pin is supported by the molding mold. After injection molding with the other end of the other pin engaged with the first pin, the first pin and the second pin are pulled out to form the first recess and the second recess. After the first molding step, a closing step is provided. The closing step closes one of the openings formed by the first pin in the first molded part by a bolt.

[0014] (4) A connector receiving unit according to one aspect of this disclosure comprises: a first molding portion integrally formed of resin material, having a base portion extending across the inside and outside of a housing housing for housing electronic components, and a bottomed cylindrical mounting portion with an opening on the outside of the housing for mounting a connector extending from an external power source; and a terminal configured to penetrate the first molding portion, having a first end exposed inside the housing for connection with the electronic components, and a second end exposed inside the mounting portion for connection with the connector, wherein a connecting hole is formed in the first molding portion. The connecting hole has: a first recess having a first opening that opens into the inner side of the housing and extends along a first direction in the base portion; and a second recess having a second opening that opens into the bottom surface of the mounting portion and extends along a second direction intersecting the first direction in the base portion. The connecting hole connects the inside and outside of the housing through the first recess and the second recess. One of the first recess and the second recess penetrates the base portion in the first direction through a through-hole and has a plug portion for closing the through-hole.

[0015] According to this solution, since both ends of a pin are supported by the molding die, it is easy to ensure the strength of the pin against injection pressure, etc. This prevents misalignment or deformation of the pin. Furthermore, it facilitates engagement of the other pin with the first pin, enabling high-precision and easy alignment between the first and second pins. Therefore, compared to the conventional configuration where the top ends of the rods are joined together, the shape accuracy and manufacturing efficiency of the connecting hole can be improved, and the durability of the molding die can be enhanced.

[0016] (2) Preferably, in the manufacturing method of the connector receiving unit of the above-mentioned (1) solution, in the above-mentioned sealing process, the above-mentioned plug is formed by molding the first molding part with resin material.

[0017] Preferably, in the connector receiving unit of the above-described scheme, the connector receiving unit includes a second forming part, which molds the first forming part and has the aforementioned plug part.

[0018] According to this solution, compared to a structure that embeds other components into a through-hole in a recess, a recess can be reliably and easily closed.

[0019] (3) Preferably, in the manufacturing method of the connector receiving unit of the above-mentioned scheme (1) or (2), when viewed from the first direction, the size of the first pin in the direction orthogonal to the second direction is different from the size of the second pin in the direction orthogonal to the first direction when viewed from the second direction. A locking portion is formed on the larger of the first pin and the second pin, and the locking portion accommodates the smaller of the first pin and the second pin, thereby restricting the relative movement of the first pin and the second pin.

[0020] According to this solution, it is easy to suppress misalignment of the first and second pins due to injection pressure during molding. Therefore, it is possible to form connecting holes with higher precision.

[0021] (5) Preferably, in the connector receiving unit of the above-mentioned (4) solution, the second forming part has a covering part covering the resistor in the housing, and the resistor is electrically connected to the electronic component.

[0022] The connector receiving unit of the above-described solution can form the connecting hole into the desired shape with high precision, thus enabling efficient gas flow through the connecting hole between the inside and outside of the housing. Therefore, even if a temperature difference arises between the inside and outside of the housing due to the heating of the resistive element, the differential pressure caused by the temperature difference can be quickly mitigated.

[0023] (7) Preferably, in any of the above-mentioned schemes (4) to (6), the cross-sectional area of ​​the second recess orthogonal to the second direction gradually increases as it moves from the connection portion with the first recess to the second opening.

[0024] According to this solution, the second pin used to form the second recess can be formed into a cone shape as it moves from the top end to the base end. Therefore, it can be used as a draft cone for the second pin, improving demolding performance.

[0025] (8) Preferably, in any of the above-mentioned schemes (4) to (7), the bolt portion is provided in the recess at a position relative to the through opening relative to the communication portion between the first recess and the second recess.

[0026] According to this solution, the obstruction between the first recess and the second recess can be prevented, and the inner and outer parts of the housing can be connected through the connecting hole.

[0027] (9) The electrical component disclosed herein comprises: a housing that houses electronic components; and a connector receiving unit of the above-described scheme disposed in the housing.

[0028] According to this solution, since it has the connector receiving unit of the above solution, it is possible to provide an electrical component that suppresses air pressure fluctuations in the housing and has excellent durability or operational reliability.

[0029] Invention Effects

[0030] According to the above solutions, the shape accuracy or manufacturing efficiency of the connecting hole and the durability of the manufacturing device can be improved. Attached Figure Description

[0031] Figure 1 This is a cross-sectional view of the electric water pump according to the first embodiment.

[0032] Figure 2 This is a perspective view of the pump section according to the first embodiment.

[0033] Figure 3 Is with Figure 2 An enlarged cross-sectional view of the portion corresponding to line III-III.

[0034] Figure 4 yes Figure 2 IV-direction view.

[0035] Figure 5 Is with Figure 3 The cross-sectional view corresponding to the VV line.

[0036] Figure 6 This is a process diagram of the first molding process in the stator manufacturing method of the first embodiment.

[0037] Figure 7 Is with Figure 6 The cross-sectional view corresponding to line VII-VII.

[0038] Figure 8 This is a process diagram used to illustrate the second molding process.

[0039] Figure 9 This is an explanatory diagram of the first molding process in the stator manufacturing method of the second embodiment.

[0040] Explanation of reference numerals in the attached figures

[0041] 1: EWP (Electrical Mounting Device)

[0042] 12: Shell

[0043] 31: Stator (Connector Receiving Unit)

[0044] 34b: Electronic components

[0045] 42: Coil (Resistor)

[0046] 44: Stator molding section (second forming section)

[0047] 45: Connector receiving part

[0048] 100: Stator Covering Section (Covering Section)

[0049] 104a: Back covering part (plug part)

[0050] 150: Connector molding section (first molding section)

[0051] 151: Receiving side terminal (terminal)

[0052] 151a: Substrate connection portion (first end)

[0053] 151c: Connector connection part (second end)

[0054] 155: Base part

[0055] 156: Installation Department

[0056] 160: Connecting hole

[0057] 161: 1st concave part

[0058] 161a: Inner opening (first opening, opening portion)

[0059] 161b: Outer opening (an opening, a through-hole)

[0060] 162: 2nd concave part

[0061] 162a: Connecting opening (connecting part)

[0062] 162b: Bottom opening (second opening)

[0063] 180: Connector

[0064] 200: First forming die (forming die)

[0065] 220: First pin (one pin, another pin, smaller pin, larger pin)

[0066] 220a: Connecting part

[0067] 221: Second pin (another pin, a pin, a larger pin, a smaller pin)

[0068] 221a: Card-connecting part. Detailed Implementation

[0069] Next, embodiments of the present disclosure will be described based on the accompanying drawings. In this embodiment, the manufacturing method of the connector receiving unit of the present disclosure, the connector receiving unit, and the electrical components are described as examples in an electric water pump (hereinafter referred to as EWP). In the embodiments or variations described below, the same reference numerals are sometimes used to refer to corresponding components, and the description is omitted. Furthermore, in the following description, expressions such as "parallel" or "orthogonal," "center," and "coaxial," which indicate relative or absolute configuration, do not merely strictly indicate such configuration, but also indicate a state in which a relative displacement of angle or distance has occurred with tolerance or to the extent that the same function can be obtained.

[0070] (First Embodiment)

[0071] [EWP1]

[0072] Figure 1 This is a cross-sectional view of EWP1.

[0073] Figure 1 The EWP (Electrical Mounting Device) 1 shown is, for example, mounted on a vehicle. The EWP 1 is at least installed in the cooling water flow path connecting the engine and the radiator. The EWP 1 allows cooling water to circulate between the engine and the radiator. The vehicle can be a hybrid vehicle or a plug-in hybrid vehicle, in addition to vehicles with only an engine.

[0074] EWP1 includes a pump section 11 and a housing 12.

[0075] Pump section 11 is, for example, an internal rotor type brushless motor. Pump section 11 is housed within housing 12. In the following description, the direction along the axis O of pump section 11 (shaft 32 described later) is sometimes simply referred to as axial, the direction intersecting axis O when viewed from the axial direction is referred to as radial, and the direction about axis O is referred to as circumferential.

[0076] <Shell 12>

[0077] The housing 12 houses the pump section 11 and forms part of the cooling water flow path. The housing 12 includes a pump cover 21 and a flow path block 22.

[0078] Pump cover 21 covers pump section 11 from a first axial side relative to pump section 11. Pump cover 21 includes pump housing section 21a and mounting flange section 21b. Pump housing section 21a is formed as a bottomed cylindrical shape with an opening facing a second axial side. Pump section 11 is housed inside pump housing section 21a. Mounting flange section 21b extends radially outward from the opening edge (second axial side end edge) of pump housing section 21a.

[0079] The flow path block 22 sandwiches the pump section 11 in the middle and overlaps it with the pump cover 21 from the second axial side. The flow path block 22 has a suction flow path 22a, a discharge flow path 22b, a connection port 22c, and a mounting flange 22d.

[0080] The intake flow path 22a is formed as a cylinder coaxial with axis O. The intake flow path 22a connects to a portion of the cooling water flow path located upstream of EWP1. Spokes 22f are formed on the inner circumferential surface of the intake flow path 22a. The spokes 22f protrude radially inward from, for example, positions on the inner circumferential surface of the intake flow path 22a that face each other radially. A hub 22g is provided at the radially inward end of each spoke 22f. The hub 22g is formed as a cylinder coaxial with axis O. The hub 22g is supported on axis O by the spokes 22f on the inner side of the intake flow path 22a.

[0081] The ejection flow path 22b surrounds the intake flow path 22a. Specifically, the cross-sectional area of ​​the ejection flow path 22b increases as it moves from one end of the circumferential flow path to the other end.

[0082] Connection port 22c is connected to the other circumferential end of the ejector flow path 22b. Connection port 22c extends away from the pump housing 21. Connection port 22c is connected to the portion of the cooling water flow path located downstream of EWP1.

[0083] The mounting flange 22d extends radially outward from the outer periphery of the ejection flow path 22b. The housing 12 of this embodiment includes: a overlapping portion 12a, which is formed by axially overlapping the mounting flange portions 21b and 22d; and an offset portion 12b, which is formed by radially offsetting the mounting flange portions 21b and 22d. The pump cover 21 and the flow path block 22 are axially assembled by fastening the mounting flange portions 21b and 22d together in the overlapping portion 12a using bolts or the like. The offset portion 12b is located in the circumferential direction of the mounting flange portions 21b and 22d. Since the mounting flange portion 21b of the pump cover 21 is located radially outward relative to the mounting flange portion 22d of the flow path block 22, the offset portion 12b has a radial gap.

[0084] <Pump Section 11>

[0085] Figure 2 This is a three-dimensional view of pump unit 11.

[0086] like Figure 1 , Figure 2 As shown, the pump unit 11 includes a stator (connector receiving unit) 31, a shaft 32, a rotor 33, and a control board 34.

[0087] like Figure 1As shown, the stator 31 is assembled into the housing 12. The stator 31 includes a stator body 41, a coil (resistor) 42, a terminal unit 43, a stator molding part (second forming part) 44, and a connector receiving part 45.

[0088] <Stator Body 41>

[0089] The stator body 41 includes a stator core 51 and an insulator 52.

[0090] The stator core 51 is formed as a cylindrical shape coaxial with the axis O. The stator core 51 is constructed by stacking annular plates in the axial direction. The annular plates are formed by punching or other processes on electromagnetic steel sheets. The stator core 51 can also be a so-called powder-pressed core or a segmented core, etc.

[0091] The stator core 51 has a yoke 51a and multiple teeth 51b.

[0092] The yoke 51a is formed as a cylinder that is coaxial with the axis O.

[0093] Tooth 51b protrudes radially inward from the inner circumferential surface of yoke 51a. Multiple teeth 51b are formed with open intervals in the circumferential direction.

[0094] Insulator 52 is mounted on stator core 51 to insulate between stator core 51 and coil 42. Insulator 52 at least surrounds the periphery of each tooth 51b. Insulator 52 may also be integrally formed on stator core 51 by insert forming or the like.

[0095] Coil 42 is constructed by winding the coil conductors corresponding to the U phase, V phase and W phase through insulator 52 on teeth 51b for each phase.

[0096] The connector unit 43 is disposed on the first side of the axial direction relative to the stator body 41. The connector unit 43 electrically connects the coil 42 to the control board 34. The connector unit 43 includes a terminal block 90 and a connector 91.

[0097] The terminal block 90 is integrally formed from a resin material or the like. When viewed axially, the terminal block 90 is formed in an arc shape centered on axis O. The terminal block 90 is assembled to the insulator 52 from the first axial side. When viewed axially, the terminal block 90 coincides with a portion of the stator body 41.

[0098] The connector 91 is formed, for example, by stamping, a sheet metal of conductive metal or the like. The connector 91 is fixed to the terminal block 90 with its protrusion in a first axial direction. Three connectors 91 are provided at circumferential intervals corresponding to the coil wires of each phase. Each connector 91 is connected to the coil wire of the respective phase.

[0099] like Figure 1 , Figure 2As shown, the stator molding section 44 is formed by molding with resin material while the stator body 41, coil 42 and connector unit 43 are assembled. The stator molding section 44 includes a stator covering section 100, an assembly piece 101, a shaft support wall 102, a spacer section 103 and a connector covering section 104.

[0100] The stator cover portion 100 is formed as a cylinder extending coaxially with the axis O. The stator cover portion 100 integrally covers the stator body 41, the coil 42, and the connector unit 43. A portion of the outer peripheral surface of the stator core 51 and a portion of the connector 91 are exposed to the outside from the stator cover portion 100. The connector 91 protrudes from the stator cover portion 100 toward a first side in the axial direction.

[0101] Assembly piece 101 extends radially outward from the second axial end of the stator cover portion 100. Assembly piece 101 is held between the pump cover 21 and the assembly flange portions 21b and 22d of the flow path block 22. Assembly piece 101 is fastened together with the assembly flange portions 21b and 22d in the overlapping portion 12a of the housing 12. Gaskets 105 are provided between assembly piece 101 and the assembly flange portion 21b of the pump cover 21, and between assembly piece 101 and the assembly flange portion 22d of the flow path block 22. This seals the connection between the pump cover 21 and the flow path block 22.

[0102] The shaft support wall 102 closes the first axial side opening in the stator cover portion 100.

[0103] Spacer portions 103 protrude from the stator cover portion 100 toward a first side in the axial direction. Multiple spacer portions 103 are provided with circumferential spacing. The connector cover portion 104 or the connector receiving portion 45 will be described later.

[0104] <Axis 32>

[0105] Shaft 32 extends axially through the inner side of stator body 41. The first axial end of shaft 32 is integrally molded to shaft support wall 102. The second axial end of shaft 32 is supported by hub 22g of flow path block 22.

[0106] <Rotor 33>

[0107] The rotor 33 is supported on the shaft 32 inside the stator core 51 and can rotate. The rotor 33 includes a rotor core 110, multiple magnets (not shown), a magnet cover 111, a rotor molding part 112, and a bushing 113.

[0108] The rotor core 110 is formed as a cylindrical shape coaxial with the axis O. The rotor core 110 is constructed by stacking annular plates in the axial direction. The annular plates are formed by punching or other processes on electromagnetic steel sheets.

[0109] Magnets are arranged side by side along the circumferential direction on the outer peripheral surface of the rotor core 110. Each magnet is configured such that its radially oriented magnetic poles are opposite poles between adjacent magnets in the circumferential direction.

[0110] The magnet cover 111 is mounted to the rotor core 110 from the radially outer side. The magnet cover 111 covers the magnets from the radially outer side and both sides in the axial direction. The magnets clamp the magnet cover 111 in the middle and face each other to the stator core 51 in the radial direction.

[0111] The rotor molding section 112 includes a rotor covering section 112a, a connecting section 112b, and an impeller section 112c.

[0112] The rotor covering portion 112a is formed as a cylindrical shape extending coaxially with the axis O. The rotor covering portion 112a integrally covers the rotor core 110 or the magnet and the magnet cover 111. The outer peripheral portion of the magnet cover 111 is exposed from the rotor covering portion 112a.

[0113] The connecting portion 112b extends radially inward from the rotor covering portion 112a. The connecting portion 112b is formed in a cylindrical shape along the axis O. The second axial end of the connecting portion 112b protrudes axially relative to the rotor covering portion 112a.

[0114] The impeller portion 112c extends radially outward from the second axial end of the connecting portion 112b. The impeller portion 112c is exposed on both the suction flow path 22a and the discharge flow path 22b.

[0115] The bushing 113 is integrally fixed to the connecting portion 112b on the inner side. The bushing 113 is formed into a cylindrical shape coaxial with the axis O. A shaft 32 passes through the inner side of the bushing 113. The bushing 113 is rotatably supported on the shaft 32. Therefore, the rotor 33 is rotatably supported on the shaft 32 via the bushing 113.

[0116] <Control board 34>

[0117] The control board 34 is disposed on the first axial side relative to the stator body 41 within the pump housing 21. The control board 34 is configured to mount a plurality of electronic components 34b on the front and back sides of the board body 34a. The control board 34 is stacked onto the stator body 41 such that the thickness direction of the board body 34a is along the axial direction. Specifically, the control board 34 is fastened to the spacer portion 103 by screws or the like, with the board body 34a supported on the spacer portion 103 from the second axial side. The board body 34a is connected to a connector 91.

[0118] <Connector Receiving Part 45>

[0119] The connector receiving part 45 is connected to a connector 180 (see reference) that extends from an external power source (battery, etc.) and is detachably mounted thereon. Figure 3The control board 34 is electrically connected to an external power source. The connector receiving part 45 is integrally formed into the stator 31 by being molded into the stator molding part 44. Specifically, the connector receiving part 45 is exposed to the inside and outside of the housing 12 by passing through the portion of the assembly piece 101 corresponding to the offset part 12b.

[0120] Figure 3 Is with Figure 2 An enlarged cross-sectional view of the portion corresponding to line III-III. Figure 4 yes Figure 2 IV-direction view. Figure 5 Is with Figure 3 The cross-sectional diagram corresponding to the VV line. For example... Figures 3-5 As shown, the connector receiving part 45 includes a connector molding part (first forming part) 150 and a plurality of receiving side terminals 151.

[0121] like Figure 3 As shown, the connector molding portion 150 is formed by molding a plurality of receiving-side terminals 151 using a resin material. The resin material constituting the connector molding portion 150 is the same as the resin material constituting the stator molding portion 44. However, the resin material constituting the connector molding portion 150 may be different from the resin material constituting the stator molding portion 44.

[0122] The connector molding section 150 includes a base section 155 and a mounting section 156.

[0123] The base portion 155 extends across the inside and outside of the housing 12 through the gap between the mounting flange portions 21b and 22d in the offset portion 12b. The base portion 155 extends from the first axial side toward the second side as it moves radially outward. Specifically, the base portion 155 includes an inner support portion 155a, a connecting portion 155b, and an outer support portion 155c.

[0124] The inner support portion 155a is the portion of the base portion 155 that is exposed within the housing 12. Specifically, the inner support portion 155a protrudes axially to a first side while a portion of the portion located within the housing 12 is embedded in the assembly piece 101.

[0125] The connecting portion 155b extends radially outward from the inner support portion 155a and axially to a second side. The connecting portion 155b axially penetrates the mounting piece 101. At least the surface of the outer surface of the connecting portion 155b facing the first axial side becomes an exposed surface not covered by the stator molding portion 44. The exposed surface of the connecting portion 155b is exposed within the housing 12. A recess 155d is formed at the boundary between the connecting portion 155b and the inner support portion 155a, recessed axially to the first side. A portion of the mounting piece 101 is embedded within the recess 155d.

[0126] The outer support portion 155c extends radially outward from the second axial end of the connecting portion 155b. The axial dimension of the outer support portion 155c gradually increases as it moves radially outward. The radially outer end of the outer support portion 155c is located radially outward from the mounting flange portion 21b.

[0127] The mounting portion 156 extends radially outward from the outer support portion 155c. The mounting portion 156 is formed as a bottomed cylindrical shape with an opening radially outward. Specifically, the mounting portion 156 includes a bottom wall portion 156a and a peripheral wall portion 156b.

[0128] The bottom wall portion 156a extends outward relative to the outer support portion 155c. Furthermore, the radially outward surfaces of the bottom wall portion 156a and the outer support portion 155c constitute the bottom surface of the mounting portion 156.

[0129] The peripheral wall portion 156b is formed into a square tube shape extending radially outward from the outer periphery of the bottom wall portion 156a. The peripheral wall portion 156b surrounds the periphery of the bottom wall portion 156a.

[0130] The receiving-side terminal 151 is configured to pass through the connector molding section 150. The receiving-side terminal 151 is formed, for example, by stamping a sheet metal of conductive metal or the like. Figure 4 , Figure 5 In the example, the receiving-side terminal 151 consists of four terminals: power supply terminal 151A, grounding terminal 151B, signal output terminal 151C, and signal input terminal 151D. In the following description, without distinguishing between the individual receiving-side terminals 151, they will be collectively referred to as receiving-side terminals 151.

[0131] like Figure 1 , Figure 3 As shown, the receiving side terminal 151 includes a substrate connection portion (first end) 151a, an embedded portion 151b, and a connector connection portion (second end) 151c.

[0132] The substrate connecting portion 151a protrudes from the inner support portion 155a toward a first axial side. The top end of the substrate connecting portion 151a is connected to the substrate body 34a. Figure 2 In the example, the substrate connection portions 151a of each receiving side terminal 151 are arranged in a row.

[0133] like Figure 1 , Figure 5As shown, the embedded portion 151b is the portion of the receiving-side terminal 151 embedded in the base portion 155. Specifically, the embedded portion 151b extends radially outward from the base end of the substrate connection portion 151a toward the second axial side, and then further extends radially outward. The embedded portion 151b reaches the bottom surface of the mounting portion 156.

[0134] like Figure 4 As shown, the connector connection portion 151c protrudes from the embedded portion 151b toward the inner side of the mounting portion 156. Inside the mounting portion 156, in the connector connection portion 151c, the signal output terminal 151C and the signal input terminal 151D are arranged side by side in two columns, as are the power supply terminal 151A and the ground terminal 151B. The layout of the substrate connection portion 151a or the connector connection portion 151c can be appropriately changed.

[0135] like Figures 3-5 As shown, a communication hole 160 is formed in the connector molding portion 150 to connect the inside and outside of the housing 12. The communication hole 160 is formed in an L-shape or T-shape by mutually orthogonal extending first recesses 161 and second recesses 162. In the following description, the extending direction of the first recess 161 is sometimes referred to as the X direction, the extending direction of the second recess 162 is sometimes referred to as the Y direction, and the direction orthogonal to the X and Y directions is sometimes referred to as the Z direction. The X direction is aligned with the axial direction, and the Y direction is aligned with the radial direction.

[0136] The first recess 161 extends linearly along the X direction (axial direction) within the base portion 155. The cross-section of the first recess 161 orthogonal to the X direction is formed as a circle. The first recess 161 has the same inner diameter along its entire length in the X direction. However, the first recess 161 may also be formed as a cone.

[0137] The first recess 161 extends through the connecting portion 155b in the X direction. Specifically, the first recess 161 has an inner opening (first opening, opening portion) 161a that opens onto the exposed surface of the connecting portion 155b. The first recess 161 has an outer opening (through opening, opening portion) 161b that opens onto a surface of the connecting portion 155b facing the side opposite to the exposed surface (hereinafter referred to as the back surface).

[0138] The second recess 162 extends linearly along the Y direction within the base portion 155. The cross-section of the second recess 162 orthogonal to the Y direction is rectangular. The second recess 162 is formed as a cone with a gradually increasing cross-sectional area from the -Y side to the +Y side (from the radial inner side to the outer side). The second recess 162 may also be formed with the same cross-sectional shape along its entire radial length.

[0139] The second recess 162 has a communicating opening (communication portion) 162a at its -Y side end, which opens into the first recess 161. The communicating opening 162a connects to a portion of the first recess 161 that is slightly outward of the center relative to the X direction. The second recess 162 communicates with the first recess 161 through the communicating opening 162a. The second recess 162 has a bottom surface opening (second opening) 162b at its +Y side end, which opens into the bottom surface of the mounting portion 156. The bottom surface opening 162b opens into the bottom surface of the mounting portion 156 in the portion between the signal output terminal 151C and the signal input terminal 151D. The second recess 162 opens into the mounting portion 156 toward the +Y side.

[0140] like Figure 5 As shown, the dimension of the connecting opening 162a in the Z direction is larger than the dimension (inner diameter) of the first recess 161 in the Z direction. Therefore, the connecting opening 162a surrounds the first recess 161 from both sides in the Z direction.

[0141] like Figure 3 , Figure 5 As shown, in the stator molding section 44, the connector cover section 104 is extended to the outside of the housing 12 while being integrally connected with the mounting piece 101. The connector cover section 104 surrounds the base section 155 on the outside of the housing 12. Specifically, the connector cover section 104 includes a back cover section (bolt section) 104a and a side cover section 104b.

[0142] The back cover portion 104a covers the portion from the back of the connecting portion 155b to the back of the outer support portion 155c. The back cover portion 104a closes the outer opening 161b. Therefore, the communicating hole 160 opens into the housing 12 through the inner opening 161a and into the mounting portion 156 through the bottom opening 162b. Furthermore, a portion of the back cover portion 104a can also enter the first recess 161 within a range that does not obstruct the communication between the first recess 161 and the second recess 162 through the communicating opening 162a. The portion of the back cover portion 104a that enters the first recess 161 is preferably contained between the opening edge of the outer opening 161b and the surface on the +X side of the inner surface of the second recess 162, and more preferably between the opening edge of the outer opening 161b and the surface on the -X side of the inner surface of the second recess 162. Therefore, it is possible to prevent the first recess 161 and the second recess 162 from being blocked, and to enable the inside and outside of the housing 12 to communicate through the connecting hole 160.

[0143] The side covering portion 104b covers the two Z-direction facing surfaces of the connecting portion 155b and the outer support portion 155c respectively. The side covering portion 104b is mounted between the back covering portion 104a and the assembly piece 101.

[0144] like Figure 3 As shown, connector 180 is detachably mounted in mounting portion 156. An insertion port (not shown) is formed on the surface of connector 180 facing the bottom surface of mounting portion 156. With connector 180 mounted in mounting portion 156, receiving terminals 151 are inserted into the insertion port. Connecting terminals (not shown) are provided within connector 180 to connect to receiving terminals 151 when they are inserted into the insertion port. Each connecting terminal is connected to an external power source via wiring. The wiring is bundled by sleeve 181 or the like and routed to the external power source.

[0145] In this embodiment, the connector 180 is preferably fitted into the mounting portion 156 via a sealing ring or the like (not shown). This restricts the entry of dust and the like into the mounting portion 156 through the space between the inner peripheral surface of the mounting portion 156 and the outer peripheral surface of the connector 180. The inner space of the mounting portion 156 is open to the atmosphere through the insertion port of the connector 180 or the sleeve 181, etc.

[0146] Next, the operation of EWP1 will be explained.

[0147] In the EWP1 of this embodiment, current is supplied to the control board 34 from an external power source via the connector receiving part 45. The current supplied to the control board 34 is supplied to the coils 42 of each phase via the connector 91 at a predetermined timing by the operation of the electronic components 34b. By supplying current to the coils 42, a magnetic field is formed in the stator core 51, generating magnetic attraction or repulsion between the magnets of the rotor 33 and the stator core 51. As a result, the rotor 33 rotates relative to the stator 31.

[0148] As the rotor 33 rotates, centrifugal force acts on the cooling water flowing into the suction flow path 22a through the impeller section 112c. Through this centrifugal force, the cooling water is sent downstream through the spray flow path 22b.

[0149] Depending on the usage or environment of the EWP1, a pressure difference may sometimes occur between the inside and outside of the housing 12. For example, when the pressure inside the housing 12 is higher than that outside, gas inside the housing 12 is discharged to the outside through the connecting hole 160. When the pressure inside the housing 12 is lower than that outside, gas outside the housing 12 flows into the inside through the connecting hole 160. In the EWP1, gas inside and outside the housing 12 enters and exits through the connecting hole 160, thereby mitigating the pressure difference between the inside and outside of the housing 12. In particular, in this embodiment, since the connecting hole 160 opens to the inner space of the mounting portion 156 through the bottom opening 162b, the intrusion of dust or liquid into the housing 12 can be suppressed.

[0150] [Manufacturing method of stator 31]

[0151] Next, the manufacturing method of the stator 31 described above will be explained. Figure 6 This is a process diagram of the first molding process in the manufacturing method of stator 31.

[0152] The stator 31 is manufactured through the first molding process and the second molding process (closing process).

[0153] In the first molding process, the connector receiving portion 45 is formed. In the first molding process, each receiving-side terminal 151 is placed in the first molding die 200, and each receiving-side terminal 151 is molded. The first molding die 200 includes a die body 201 that forms a cavity 200a, and a forming pin 202 that forms a connecting hole 160.

[0154] The mold body 201 includes an upper mold 210, a lower mold 211, and a sliding mold 212.

[0155] The upper mold 210 and the lower mold 211 are the parts that form the outer surface of the connector molding portion 150, and are arranged to face each other in the X direction. For example, the upper mold 210 is configured to be movable in the X direction relative to the lower mold 211. The upper mold 210 holds the substrate connection portion 151a of the receiving side terminal 151 when the first molding mold 200 is closed.

[0156] The sliding mold 212 is the part that shapes the inner surface of the mounting portion 156. The sliding mold 212 is configured to move in the Y direction relative to the upper mold 210 and the lower mold 211. The sliding mold 212 holds the connector connection portion 151c of the receiving side terminal 151 when the first forming mold 200 is closed.

[0157] The forming pin 202 includes a first pin 220 for forming the first recess 161 and a second pin 221 for forming the second recess 162.

[0158] The first pin 220 is cylindrical. During mold closing, the first pin 220 penetrates the cavity 200a in the X direction and is positioned between the upper mold 210 and the lower mold 211. Alternatively, the first pin 220 may be configured to move integrally with the upper mold 210 and support the lower mold 211 during mold closing. Or, the first pin 220 may be integrally formed with the lower mold 211 and support the upper mold 210 during mold closing.

[0159] The second pin 221 protrudes from the sliding mold 212 toward the -Y side in a cantilever form. The second pin 221 is formed into a square column shape that gradually tapers at the top as it moves toward the -Y side.

[0160] Figure 7 Is with Figure 6 The cross-sectional view corresponding to line VII-VII.

[0161] like Figure 7 As shown, in the second pin (the larger pin) 221, the Z-direction dimension at the -Y side end is larger than the outer diameter of the first pin (the smaller pin) 220. A locking portion 221a is formed at the -Y side end (the other end) of the second pin 221. The locking portion 221a extends through the second pin 221 in the X direction. When viewed from the X direction, the locking portion 221a is formed as a recessed semi-circular shape, mimicking the outer peripheral surface of the first pin 220. During mold closing, the outer peripheral surface of the first pin 220 abuts against the inner peripheral surface of the locking portion 221a. In this state, a portion of the first pin 220 is housed inside the locking portion 221a, thereby restricting the movement of the second pin 221 relative to the first pin 220 in the Z direction.

[0162] like Figure 6 As shown, when performing the first molding process using the first molding die 200 described above, the receiving terminal 151 is placed in the first molding die 200, and the first molding die 200 is closed. In the receiving terminal 151, with the embedded portion 151b penetrating the cavity 200a, the substrate connecting portion 151a is held in the upper die 210, and the connector connecting portion 151c is held in the sliding die 212. With the die closing, the first pin 220 is supported in a double-support configuration between the upper die 210 and the lower die 211. On the other hand, the second pin 221 is supported in a double-support configuration between the sliding die 212 and the first pin 220 because the engaging portion 221a engages with the first pin 220.

[0163] After the first molding die 200 is closed, molten resin material is filled into the cavity 200a of the first molding die 200. The resin material then fills the cavity 200a to cover the area around the receiving terminal 151 and the molding pin 202. By curing the resin material, the connector molding portion 150 (see reference 150) is formed. Figure 3 It is injection molded as a one-piece product.

[0164] After the resin material has cured, the first molding die 200 is opened. Specifically, after releasing the holding of the connector connection portion 151c, the sliding die 212 is moved towards the +Y side. The second pin 221 then moves towards the +Y side together with the sliding die 212, thereby pulling the second pin 221 out of the connector molding portion 150. After releasing the holding of the substrate connection portion 151a, the upper die 210 is moved towards the +X side. The first pin 220 then moves towards the +X side together with the upper die 210, thereby pulling the first pin 220 out of the connector molding portion 150. As a result, a first recess 161 is formed in the portion of the connector molding portion 150 after the first pin 220 has retracted, and a second recess 162 is formed in the portion of the connector molding portion 150 after the second pin 221 has retracted.

[0165] Figure 8 This is a process diagram used to illustrate the second molding process. In the following description, the periphery of the connector receiving part 45 in the second molding process will be mainly described.

[0166] In the second molding process, the stator body 41, coil 42, connector unit 43 and connector receiving part 45 are placed as molded products in the second molding mold 250 and molded integrally using resin material.

[0167] The second forming mold 250 includes an upper mold 251 and a lower mold 252. During mold closing, the upper mold 251 and lower mold 252 hold the portion of the connector molding section 150 from the outer support portion 155c to the mounting portion 156. The cavity 250a of the second forming mold 250 has either an assembly piece forming portion 250b or a covering portion forming portion 250c. The assembly piece forming portion 250b in the second forming mold 250 is a space located on the +X side relative to the outer support portion 155c. The covering portion forming portion 250c in the second forming mold 250 is a space surrounding both sides in the -X side and the Z direction relative to the outer support portion 155c. The covering portion forming portion 250c has an outer opening 161b of the first recess 161.

[0168] When performing the second molding process using the second molding die described above, each molded part is placed inside the second molding die 250, and the second molding die 250 is closed. After the second molding die 250 is closed, molten resin material is filled into the cavity 250a of the second molding die 250. The resin material then fills the cavity 250a to cover the periphery of each molded part. At this time, the resin material also fills the assembly piece forming portion 250b or the covering portion forming portion 250c, thereby covering the periphery of the base portion 155 with resin material. That is, the outer opening 161b of the first recess 161 is closed by the resin material. Then, by curing the resin material, the stator molding portion 44 is injection molded.

[0169] After the resin material has cured, the stator 31 is formed as a secondary molded product by opening the second molding mold 250. That is, the stator 31 is formed with the outer opening 161b of the first recess 161 closed by the stator molding part 44.

[0170] Thus, in this embodiment, the configuration is as follows: in the first molding process, both ends of the first pin 220 are supported on the first forming mold 200 (upper mold 210 and lower mold 211), one end of the second pin 221 is supported on the first forming mold 200 (sliding mold 212), and the other end of the second pin 221 is supported on the first pin 220.

[0171] According to this configuration, since both ends of the first pin 220 are supported by the first molding die 200, it is easy to ensure the strength of the first pin 220 against injection pressure, etc. Therefore, misalignment or deformation of the first pin 220 can be suppressed. Furthermore, it is easy to make the second pin 221 abut against the first pin 220, thus enabling high-precision and easy alignment between the first pin 220 and the second pin 221. Therefore, compared to the conventional configuration where the top ends of the rods are joined together, the shape accuracy or manufacturing efficiency of the connecting hole 160 can be improved, and the durability of the first molding die 200 can be enhanced.

[0172] In this embodiment, the configuration is as follows: in the second molding process, the outer opening 161b of the first recess 161 is closed by molding the connector molding portion 150 using the stator molding portion 44.

[0173] According to this configuration, compared to a configuration in which other components are embedded in the outer opening 161b of the first recess 161, the outer opening 161b can be reliably and easily closed.

[0174] In this embodiment, the configuration is as follows: the stator molding part 44 has a stator covering part 100 covering the coil 42 inside the housing 12.

[0175] According to this configuration, as described above, the connector receiving portion 45 of this embodiment can form the connecting hole 160 into a desired shape with high precision, thus enabling efficient gas entry and exit through the connecting hole 160 inside and outside the housing 12. Therefore, even if a temperature difference is generated inside and outside the housing 12 due to the heating of the coil 42, the differential pressure inside and outside the housing 12 caused by the temperature difference can be quickly alleviated.

[0176] In this embodiment, the cross-sectional area of ​​the second recess 162 gradually increases from the connecting opening 162a to the bottom opening 162b.

[0177] According to this configuration, the second pin 221 used to form the second recess 162 can be formed into a cone shape as it moves from the top end to the base end. Therefore, it can be used as a draft cone for the second pin 221, improving demolding performance.

[0178] In this embodiment, the configuration is as follows: a locking portion 221a is formed on the second pin 221, the locking portion 221a receives the first pin 220 and restricts the movement of the first pin 220 relative to the second pin 221.

[0179] With this configuration, it is easy to suppress misalignment of the first pin 220 and the second pin 221 due to injection pressure during molding. Therefore, the connecting hole 160 can be formed with higher precision.

[0180] Since the EWP1 of this embodiment has the stator 31 of this embodiment described above, it is possible to provide an EWP1 that suppresses air pressure fluctuations within the housing 12 and has excellent durability or operational reliability.

[0181] (Second Implementation)

[0182] Figure 9 This is an explanatory diagram of the first molding process of the second embodiment. In the second embodiment, an engaging portion is formed on the first pin 220, which differs from the first embodiment.

[0183] exist Figure 9 In the formed pin 202 shown, the first pin 220 is formed as a square column extending in the X direction. The first pin 220 passes through the cavity 200a with one side of its outer peripheral surface facing the +Y side. An engaging portion 220a is formed in the first pin 220, opening towards the +Y side. The engaging portion 220a is, for example, circular when viewed from the Y direction.

[0184] The second pin 221 is formed as a cylinder extending in the Y direction. The outer diameter of the second pin (smaller pin) 221 is smaller than the Z-direction dimension of the first pin (larger pin) 220. The -Y side end of the second pin 221 engages with the engaging portion 220a during mold closing. Thus, the second pin 221 is supported by the first pin 220.

[0185] Even with this configuration, misalignment or deformation of the first pin 220 can be suppressed during the first molding process. Consequently, the second pin 221 can easily abut against the first pin 220, thus enabling high-precision and easy alignment between the first pin 220 and the second pin 221.

[0186] (Other variations)

[0187] While the preferred embodiments of this disclosure have been described above, this disclosure is not limited to these embodiments. Additions, omissions, substitutions, and other modifications can be made to the configuration without departing from the spirit of this disclosure. This disclosure is not limited to the foregoing description but only to the appended claims.

[0188] For example, in the above embodiment, EWP1 was described as an electrical component housing electronic components 34b within the housing 12, but the configuration is not limited to this. The configuration disclosed herein can also be used in electrical components other than EWP1. Examples of electrical components other than EWP1 include motors, vehicle ECUs (Electronic Control Units), etc. In this case, the electronic components (resistors) constituting the electrical component can also be molded in the second molded body.

[0189] In the above embodiment, the configuration in which the coil 42 and the like are molded in the second molded body has been described, but it is not limited to this configuration. The second molded body can be configured to at least close the outer opening 161b, and it is also possible not to mold anything other than the connector receiving part 45.

[0190] In the above embodiment, a configuration in which a portion of the stator molding portion 44 (back covering portion 104a) is used as a bolt has been described, but the configuration is not limited to this. The bolt may also be formed by a component independent of the molding portion. In this case, the bolt can close the outer opening 161b by embedding or bonding it to the outer opening 161b, etc.

[0191] In the above embodiment, the configuration in which the first pin 220 and the second pin 221 are supported by an engagement portion formed in one of the pins has been described, but the configuration is not limited to this. For example, the second pin 221 may also abut (engage) only with the outer peripheral surface of the first pin 220.

[0192] In the above embodiment, the configuration in which the first pin 220 is supported by the first forming mold 200 in a double-support manner and the top end of the second pin 221 abuts (engages) with the first pin 220 has been described, but the configuration is not limited to this. It is also possible for the second pin 221 to be supported by the first forming mold 200 in a double-support manner and for the top end of the first pin 220 to engage with the second pin 221. In this case, the through-hole in the opening formed by the second pin 221, located on the side opposite to the bottom opening 162b, is closed by the bolt portion.

[0193] In the above embodiment, the configuration in which the first recess 161 and the second recess 162 are orthogonal to each other has been described as an example, but the configuration is not limited to this. The first recess 161 and the second recess 162 can be configured to connect the inside and outside of the housing 12, or they can intersect at an angle other than a right angle.

[0194] In the above embodiments, the case of forming a connecting hole 160 has been described, but the number or layout of the connecting holes 160 can be appropriately changed.

[0195] In the above embodiment, the configuration in which the first recess 161 and the second recess 162 communicate with each other to form the communicating hole 160 has been described, but the configuration is not limited to this. Other recesses besides the first recess 161 and the second recess 162 may also be made to communicate.

[0196] Furthermore, without departing from the spirit of this disclosure, the constituent elements in the above embodiments can be appropriately replaced with known constituent elements, and the above variations can also be appropriately combined.

Claims

1. A method for manufacturing a connector receiving unit, the connector receiving unit being disposed in a housing housing electronic components, and electrically connecting the electronic components to an external power source by means of a connector extending from an external power source, the method for manufacturing the connector receiving unit being characterized in that... The connector receiving unit described above includes: The first molding part, integrally formed of resin material, has a base part extending across the inside and outside of the aforementioned housing, and a bottomed cylindrical mounting part opening on the outside of the aforementioned housing; and The terminal is configured to penetrate the first formed portion, having a first end exposed within the housing for connection with the electronic component, and a second end exposed within the mounting portion for connection with the connector. A communicating hole is formed in the first forming portion, the communicating hole having: a first recess having a first opening that opens into the inner side of the housing and extends along a first direction in the base portion; and a second recess having a second opening that opens into the bottom surface of the mounting portion and extends along a second direction intersecting the first direction in the base portion, the communicating hole enabling communication between the inside and outside of the housing through the first recess and the second recess. The manufacturing method of the connector receiving unit includes a first molding step, wherein the first molding step forms the first molded part by molding with a first pin forming the first recess, a second pin forming the second recess, and the terminal in a molding die using a resin material. In the first molding process described above, one of the first and second pins is supported at both ends by the molding die, and the other pin is supported at one end by the molding die. After injection molding with the other end of the other pin engaged with the first pin, the first and second pins are pulled out, thereby forming the first and second recesses. After the first molding process described above, there is a closing process, which closes one of the openings formed by the pin in the first forming part by means of a bolt.

2. The method for manufacturing the connector receiving unit according to claim 1, wherein, In the above-mentioned sealing process, the above-mentioned plug is formed by molding the first molding part using resin material.

3. The method for manufacturing the connector receiving unit according to claim 1 or claim 2, wherein, When viewed from the first direction, the dimension of the first pin in the direction orthogonal to the second direction is different from the dimension of the second pin in the direction orthogonal to the first direction when viewed from the second direction. The larger of the first and second pins has an engaging portion that accommodates the smaller of the first and second pins, thereby restricting the relative movement of the first and second pins.

4. An electrical component, characterized in that, have: The casing that houses the electronic components; The first molding part, integrally formed of resin material, has a base part extending across the inside and outside of the aforementioned housing, and a bottomed cylindrical mounting part with an opening on the outside of the aforementioned housing for mounting a connector extending from an external power source; and The terminal is configured to penetrate the first formed portion, having a first end exposed within the housing for connection with the electronic component, and a second end exposed within the mounting portion for connection with the connector. A communicating hole is formed in the first forming portion, the communicating hole having: a first recess having a first opening that opens into the inner side of the housing and extends along a first direction in the base portion; and a second recess having a second opening that opens into the bottom surface of the mounting portion and extends along a second direction intersecting the first direction in the base portion, the communicating hole enabling communication between the inside and outside of the housing through the first recess and the second recess. One of the first and second recesses penetrates the base portion in the first direction through a through opening. Equipped with a bolt that closes the aforementioned through-hole, It includes a second forming part, which molds the first forming part and has the aforementioned plug part. The second forming part described above has a covering part for covering the resistor within the housing. The resistor is electrically connected to the electronic component.

5. The electrical component according to claim 4, wherein, The cross-sectional area of ​​the second recess, which is orthogonal to the second direction, gradually increases from the connection portion with the first recess to the second opening.

6. The electrical component according to claim 4 or claim 5, wherein, The aforementioned plug portion is located in one of the aforementioned recesses at a position relative to the connecting portion between the aforementioned first recess and the aforementioned second recess, which is biased towards the aforementioned through opening.

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