Motor and method for its manufacture

Abstract

Engine, with: a motor body (2) containing a brush holder (7) which holds a plurality of energy supply brushes (8, 108); and a gearbox housing (21) which accommodates a speed reduction mechanism that reduces the rotational speed generated by the main motor body (2) and outputs a rotation at reduced speed a control circuit section (25) which contains the following: a driver control IC (41) that controls the rotation of the motor main body (2); and a base (31) holding a plurality of terminals (38) which electrically connects the driver control IC (41) to the plurality of power supply brushes (8, 108) of the brush holder (7), wherein the base (31) holds the brush holder (7); and a rotation sensor (21cc) that detects the rotation of the main engine body (2), wherein the rotation sensor (21cc) is held by the base (31); and wherein the base (31) includes an extension (31c) which holds the rotation sensor (21c) at a distal end thereof; and wherein the extension (31c) is curved to bypass a screw (27) which is used to create a connection between the main engine body (2) and the gearbox housing (21).

Description

[0001] The present invention relates to a motor comprising a control circuit section in which a driver control IC is installed, and also relates to a manufacturing method for such a motor.

[0002] An earlier proposed motor, used, for example, in an electric window operating system, comprises a motor body, a speed reduction device, and a control circuit section. The motor body rotates after excitation occurs. The speed reduction device reduces the rotational speed generated in the motor body and outputs a rotation at a reduced speed. The control circuit section controls the rotation of the motor body. Recently, a control circuit section of the type previously described has been proposed that includes a driver control IC (an IC containing a transistor).

[0003] For example, the unexamined Japanese patent publication JP 2002-511728A discloses a motor that does not have a driver control IC. In this motor, connections extending from a receiver, which holds a circuit board of a control circuit section, are connected to the circuit board at a junction point. The junction point also serves as a mounting structure that holds the circuit board.

[0004] In a case where vibrations or shocks applied to the motor are transmitted to the circuitry, the mounting structure, which forms the electrical connection of the circuit board and holds the circuit board, receives significant mechanical stress, according to unexamined Japanese patent publication No. JP 2002-511728A (equivalent to US 6,577,029 B1). This structure provides the electrical connection to the circuit board and holds the circuit board in place. Consequently, in certain situations, electrical connections on the circuit board may break, leading to motor malfunction.

[0005] DE 43 37 390 A1 discloses a drive unit for adjustment systems in motor vehicles comprising an electric motor, a gearbox connected to the motor shaft and the adjustment system, and an electronic module with an electrical circuit for supplying power to the electric motor. At least a part of the stator and / or the stationary commutation device of the electric motor is connected to a load-bearing component of the electronic motor.

[0006] EP 0 618 659 A1 discloses a commutator motor-gearbox drive unit, in particular a motor vehicle window regulator drive. In order to integrate electronics with the drive unit while simplifying manufacturing and assembly and maintaining a compact design, a printed circuit board (PCB) housing the electronics and simultaneously serving as a brush plate for the commutator motor is arranged with an electronics housing parallel to the opposing housing flanges of the motor housing and the gearbox housing of the drive unit. The PCB is covered on one axial end face by the motor housing and the electronics housing, and on the other axial end face by the gearbox housing.

[0007] DE 103 42 756 A1 describes a motor with a connector housing. A control panel is held in a gearbox housing of the motor, and a connector housing is connected to the gearbox housing. The connector housing is separate from the gearbox housing and has a plurality of connection terminals secured to the connector housing. The connection terminals of the connector housing are connected to electrical switching components of the control panel. The connection terminals are also connected to corresponding terminals of an external connector when the external connector is connected to the connector housing.

[0008] DE 103 52 079 A1 describes an electric motor, in particular for adjusting moving parts in motor vehicles, with an electronic unit in sandwich construction, which has a first electrically conductive substrate and a second electrically conductive substrate, between which power components are arranged and electrically connected to both substrates, and the second substrate is equipped with further electronic components on a side facing away from the first substrate, wherein the first substrate is designed as a conductive stamped grid, which together with the second substrate is overmolded with a plastic body in such a way that extensions of the stamped grid protrude from the plastic body, forming an electrical and / or mechanical interface for connecting further motor components.

[0009] The present invention addresses the disadvantages described above. It is therefore an object of the present invention to provide a motor in which mechanical stress applied to an electrical connection of a control circuit component is mitigated in order to limit motor malfunction. Another object of the present invention is to provide a manufacturing method for such a motor.

[0010] To solve the problem described in the present invention, a motor is provided comprising a motor body and a control circuit section. The motor body includes a brush holder that holds a plurality of power supply brushes. The control circuit section includes a driver control IC and a base. The driver control IC controls the rotation of the motor body. The base holds a plurality of terminals that electrically connect the driver control IC to the plurality of power supply brushes of the brush holder. The base is held in position by the brush holder.

[0011] To achieve the objectives of the present invention, a motor is also provided, comprising a motor body, a gearbox housing, and a control circuit section. The motor body contains a brush holder which holds a plurality of energy-supply brushes. The gearbox housing incorporates a speed reduction mechanism that reduces the rotational speed generated in the motor body and outputs the rotation at a reduced speed. The control circuit section includes a driver control IC and a base.

[0012] The driver control IC controls the rotation of the motor body. The base houses a variety of terminals that electrically connect the driver control IC to the brush holder's energy-supplying brushes. The motor body and gearbox housing are mounted together in a configuration where the base is supported by the brush holder.

[0013] To solve the aforementioned problem of the present invention, a manufacturing method for the motor is also provided. According to the manufacturing method, a base of a control circuit part, which holds a plurality of connections, is installed on a brush holder of a motor body, which holds a plurality of energy supply brushes, so that the base of the control circuit part is held by the brush holder, and a driver control IC of the control circuit part, which controls the rotation of the motor body, is electrically connected to the brush holder via the plurality of connections. Then, the motor body, which includes the brush holder, is assembled with a gearbox housing, which accommodates the speed reduction mechanism that reduces the speed generated by the motor body and outputs a reduced speed, after the base of the control circuit part has been installed on the brush holder.

[0014] The present invention, together with its additional aims, features and advantages, can be better understood with reference to the following description, the attached claims and the accompanying drawings, which show: Fig. 1 a cross-sectional view of an assembled motor according to a first embodiment of the present invention; Fig. 2. An expanded cross-sectional view of the motor of the first embodiment, illustrating a state before assembly of the motor; Fig. 3A an end view showing a gearbox housing side end face of a brush holder installed in a motor body of the motor of the first embodiment; Fig. 3B an enlarged perspective view of IIIB in Fig. 3A, showing an installation part of the brush holder; Fig. 4 a cross-sectional view of a motor according to a second embodiment of the present invention; Fig. 5 a partial cross-sectional view of the motor, showing a state before assembly of the motor of the second embodiment; and Fig. 6 a cross-sectional view along line VI-VI in Fig. 4. (First embodiment)

[0015] A motor for an electric vehicle window actuation system according to the first embodiment of the present invention is described with reference to the accompanying drawings.

[0016] As in the Fig. 1 and Fig. As shown in Figure 2, the motor 1 of the present embodiment comprises a motor body 2 and a speed reduction device (speed reduction mechanism) 3. The motor body 2 rotates when excitation occurs. The speed reduction device 3 reduces the rotational speed generated by the motor body 2 and outputs a reduced rotational speed.

[0017] The motor body 2 contains a yoke housing (hereinafter referred to simply as a yoke) 4, two permanent magnets 5, an armature 6, a brush holder 7, and two energy supply brushes 8. The yoke 4 is designed as a generally flat, cup-shaped body with a closed bottom. The magnets 5 are attached to an inner circumferential surface of the yoke 4. The armature 6 is rotatably mounted in the yoke 4.

[0018] The brush holder 7 is made of a resin material and comprises a holder body 7a, a flange 7b, an extension 7c, and a circuit mounting section 7d. The holder body 7a is configured to be received substantially within an opening of the yoke 4. A bearing 9 is attached to a central hole of the holder body 7a to rotatably hold the distal end of a rotating shaft 10 of the armature 6. The energy supply brushes 8 are slidably held by the holder body 7a on an inner surface of the yoke 4 of the holder body 7a in such a way that the energy supply brushes 8 are pressed radially inward against a commutator 11 attached to the rotating shaft 10 to form an electrical contact between them.

[0019] The flange 7b extends radially outward from the main body of the holder 7a in a direction away from the rotating shaft 10. The extension 7c is located on a lateral side of the yoke 4 and extends from an outer circumferential portion of the flange 7b in a direction parallel to a plane of a flat surface 4a of the yoke 4, i.e., it extends in a continuation direction of a wheel mounting section 21c with respect to a worm gear mounting section 21b of a gear housing 21, which will be described further below. The switching mounting section 7d, which accommodates a control switching element 25, is formed in a distal end of the extension 7c. The control switching element 25 controls the rotation of the main body of the motor 2. The switching mounting section 7d extends in the same direction as the extension direction of the wheel mounting section 21c with respect to the worm gear mounting section 21b of the gear housing 21.

[0020] As in Fig. As shown in Figure 3A, the circuit receiving section 7d has a receiving recess 7e which has a generally rectangular cross-section. An upper half of the control circuit part 25 is essentially inserted into the receiving recess 7e as shown. Fig. 2. A plurality (four in the present embodiment, but also any other number in some cases) of the installation pieces 7f is provided in an inner surface of the receiving recess 7e, and extends to an opening of the receiving recess 7e and to retaining corners of a base 31 of the control circuit part 25.

[0021] As in Fig. As shown in Figure 3B, the mounting pieces 7f can be configured as deformable cantilever struts (snap-in locks), each having a hook 7fa at an axial distal free end for engaging a surface of the base 31. The mounting pieces 7f in the form of deformable cantilever struts enable a snap-fit ​​or snap-in attachment of the base 31 of the control circuit part 25 to the mounting pieces 7f at the time of installation of the control circuit part 25 in the receiving recess 7e in a direction generally parallel to an axis of rotation of the rotating shaft 10 of the motor body 2. This type of snap-in attachment allows the control circuit part 25 to be detachably fixed in the receiving recess 7e of the brush holder 7.The removable or detachable fastening of the control circuit part 25 allows the entire control circuit part 25 to be easily replaced with a new one in the event of a malfunction. Furthermore, the snap-in fastening allows for easy installation of the control circuit part 25 in the receiving recess 7e of the brush holder 7 compared to other types of fastening devices, such as screws.

[0022] Instead of the cantilever strut snap fastener described above, a cylindrical snap fastener (using generally cylindrical projections and generally cylindrical receptacles that can snap together, a spherical snap fastener using spherical projections and generally spherical recesses or receptacles that can snap together), or any other type of snap fastener may be used. For example, in the case of the cylindrical snap fastener, the cylindrical projections may be configured to engage in the receiving recess 7e instead of the mounting pieces 7f, and the cylindrical receptacles may be configured in the base 31 to engage with the cylindrical projections.In the case of the spherical snap connection, the spherical projections can also be configured to project into the receiving recess 7e instead of the installation pieces 7f, and the spherical containers or recesses in the base 31 can be configured to engage with the spherical projections. Furthermore, if desired, screws or other fasteners can be used to secure the base 31 of the control circuit part 25 in the receiving recess 7e. Also, if desired, a bonding or melting technique can be used to permanently fix the base 31 of the control circuit part 25 in the receiving recess 7e.

[0023] According to the Fig. 1 and Fig. 2 A metal cover 26 is installed on the circuit receiving section 7d (the brush holder 7), which receives the control circuit part 25, via installation parts 26b, 26c of the metal cover 26 to close the opening of the circuit receiving section 7d (the receiving recess 73). The metal cover 26 has a receiving recess 26a that receives the rest of the control circuit part 25.

[0024] As further in the Fig. 1 and Fig. As shown in Figure 2, a generally rectangular tubular connecting housing section 7g projects from the circuit receiving section 7d in a direction that is generally parallel to the axial direction of the rotating shaft 10. Electrical contacts 35a of a connector main body 35, which is provided in the control circuit part 25, are inserted into the interior of the connector housing section 7g to form a connector 36 of the motor 1.

[0025] The flange 7b, the extension 7c, and the opening of the circuit-receiving section 7d (receiving recess 7e) of the brush holder 7 are covered by a sealing element 15 made of a flexible material, such as an elastomer. More specifically, the flange 7b and the extension 7c, covered by the sealing element 15, engage with an opening in the yoke 4 and an opening in a mounting section 21a of the gearbox housing 21, to which the yoke 4 is attached. With this arrangement, the opening of the yoke 4 and the opening of the mounting section 21a of the gearbox housing 21 are effectively sealed by the sealing element 15, which covers the flange 7b and the extension 7c. The opening of the circuit receiving section 7d, which is covered by the sealing part 15, engages with seals and seals an opening in the cover 26, which closes the circuit receiving section 7d.

[0026] Furthermore, terminals 12, which are made of metal plates, are embedded in the brush holder 7, i.e., they are contained within it by means of insert forming. The base ends of the terminals 12 are exposed at the yoke 4 or its inner surface of the holder's main body 7a and are electrically connected to the energy supply brushes 8 via connecting wires. Contacts 12a, formed at the distal ends of the terminals 12, project into the interior of the circuit receiving section 7d (the receiving recess 7e) and are electrically connected to the control circuit part 25.

[0027] The speed reduction device 3 includes the gearbox housing 21, a worm shaft 22, a worm wheel 23 and a coupling 24. The worm shaft 22 and the worm wheel 23 form the speed reduction mechanism.

[0028] The gearbox housing 21 is made of a resin material and contains the fixing section 21a, the worm gear mounting section 21b, and the gear mounting section 21c. The fixing section 21a is configured according to the shape of the flange 4b ​​formed at the opening of the yoke 4. The flange 4b ​​is fastened to the fixing section 21a by means of screws 27. The fixing section 21a then works together with the flange 4b ​​to clamp the flange 7b and the extension 7c of the brush holder 7 between them via the sealing element 15. With this design, the opening of the yoke 4 and the opening of the fixing section 21a are effectively sealed by the sealing element 15.

[0029] The worm gear receiving section 21b is designed as a tubular body extending along an imaginary continuation line of the rotating shaft 10. The worm gear receiving section 21b rotatably holds the worm shaft 22 within it. The coupling 24 is provided on the side of the motor main body 2, specifically on the interior of the worm gear receiving section 21b. The coupling 24 establishes a connection between the worm shaft 22 and the rotating shaft 10 in such a way that the transmission of a driving force between them is enabled. More specifically, when the driving force is transmitted from the rotating shaft 10 to the coupling 24, the coupling 24 transmits the driving force from the rotating shaft 10 to the worm shaft 22.Conversely, when a driving force is transmitted from the worm shaft 22 to the clutch 24, the clutch 24 blocks the rotation of the worm shaft 22 in order to limit the transmission of the driving force from the worm shaft 22 to the rotating shaft 10. That is, the clutch 24 is designed to limit the rotation of the motor 1 that would be caused by the force applied from a load side (e.g., a load applied downwards to a window pane, not shown) by the electric window operating system. In this way, unintentional opening movement of the window pane can be advantageously limited.

[0030] As in Fig. As shown in Figure 2, at the time of assembly of the main motor body 2 (yoke 4) and the speed reduction device 3 (the gearbox housing 21), a drive-side rotary body 24a, which forms part of the coupling 24, is pre-installed at the distal end of the rotating shaft 10. Then, at the time of assembly of the main motor body 2 with the speed reduction device 3, the drive-side rotary body 24a is received in a main body of the coupling 24 to complete the assembly of the coupling 24. An annular sensor magnet (a ring magnet) 24b is installed on the drive-side rotary body 24a so that it rotates together with the drive-side rotary body 24a. The sensor magnet 24b is designed to, for example, sense the rotational speed of the rotating body 24a and thereby the rotational speed of the rotating shaft 10, which is rotated together with the rotating body 24a.

[0031] The gear mounting section 21c is designed as a circular, disc-shaped body extending from the worm mounting section 21b. The gear mounting section 21c rotatably holds the worm gear 23 within it. A flat surface 21d of the gear mounting section 21c extends continuously from the flat surface 24a of the yoke 4. The gear housing 21 and the yoke 4 are shaped to have a low profile, thus achieving a low profile for the entire motor 1. An interior of the worm mounting section 21b and an interior of the gear mounting section 21c are connected to each other at a junction where the worm shaft 22 and the worm gear 23 mesh. The output shaft 23a is connected to the worm gear 23 at one end and to a window regulator (not shown) at the other end.When the main motor body 2 is controlled and thereby set in rotation by the control circuit part 25, the output shaft 23a rotates via the worm shaft 22 and the worm wheel 23 to drive the window regulator, so that the window pane can be raised or lowered by the window regulator.

[0032] The control circuit element 25, which controls the opening and closing of the window pane, will now be described in more detail. The control circuit element 25 includes the base 31, which is made of a resin material and configured to have a general plate shape. The base 31 includes mounting surfaces 31a, 31b, each arranged on opposite sides of the base 31. The base 31 is received in receiving recesses 7e, 26a such that the mounting surfaces 31a, 31b are perpendicular to the flat surface 4a of the yoke 4 and also to the flat surface 21b of the wheel mounting section 21c. Furthermore, the base 31 is held by the installation parts 7f, which are arranged in the receiving recess 7e.

[0033] An inductor 32 and capacitors 33, 34 are mounted on the mounting surface 31a of the base 31, which is located on the side of the base 31 opposite the cover 26. The inductor 32 and the capacitors 33, 34 are provided for the purpose of limiting electromagnetic interference signals caused by the sliding contact of the power supply brushes 8 and the PWM control operation of a driver control IC 41.

[0034] The connector main body 35, which holds the electrical contacts 35a, projects from the mounting surface 31a. Each contact 35a of the connector main body 35 is received in the connector housing section 7g, which is provided in the circuit mounting section 7d, to form the connector 36 of the motor 1. A vehicle chassis-side connector (not shown) is electrically connected to the connector 36 in the axial direction of the rotating shaft 10 to supply electrical power from the vehicle chassis side.

[0035] Furthermore, electrical contacts 37 protrude from the mounting surface 31a and engage with, i.e., are connected to, contacts 12a, which project into the interior of the circuit receptacle 7b of the brush holder 7. The contacts 37 can be engaged simultaneously with the contacts 12a when the control circuit part 25 is installed in the receptacle 7e of the brush holder 7. When the contacts 37 are connected to the contacts 12a of the brush holder 7, electrical energy is supplied from the vehicle's power supply to the energy-supplying brushes 7 via the connector 36 and the control circuit part 25.

[0036] The driver control IC 41 is securely mounted on the mounting surface 31b on the side of the cover 26 (the side of the gearbox housing 21) of the base 31. As shown in Fig. As shown in Figure 3A, the driver-control IC 41 comprises an IC body 41a and a plurality of electrical leads 41b. The IC body 41a is shaped in a generally rectangular plate form. The leads 41b project from the IC body 41a in a longitudinal direction. The IC body 41a contains a driver circuit and a control circuit, which are configured as a single chip or as many chips and are encapsulated in resin. The driver circuit includes, for example, a power MOSFET that supplies the electrical driver current to the motor body 2. The control circuit performs, for example, the PWM control operation and an anti-pinch control operation to limit the pinching of an object by the window pane. The leads 41b are connected to the circuits of the IC body 41a.The terminals 38 are, for example, embedded or recessed in the base 31 by means of insert forming, and the conductor contacts 41b are welded or soldered to predetermined parts of the terminals 38. Furthermore, the terminals 38 are connected to the choke coil 32 and the capacitors 33, 34. The contacts 35a of the connector 36 and the contacts 37, which are connected to the contacts 12a of the brush holder 7, are also formed integrally or as a single piece with the terminals 38.

[0037] As further in Fig. As shown in Figure 3A, an extension 31c is formed in the base 31 and extends to a point adjacent to the rotating shaft 10, more specifically, to a point adjacent to the sensor magnet 24 of the drive-side rotating body 24a of the coupling 24. A Hall-effect IC 42 is installed at a distal end of the extension 31c. Screw holes 4c1–4c3 are provided on a flange 4b ​​of the yoke 4 to accommodate screws 27. Among the screw holes 4c1–4c3, screw hole 4c1, which is adjacent to the extension 31c, is positioned closer to the center in the lateral direction of the yoke 4 (the vertical center of the yoke 4). Fig. 3A). The extension piece 31c is bent or curved so that it bypasses the screw hole 4c1, as shown in Fig. 3A is shown. More specifically, the screw hole 4c1 is positioned closer to the center in the width direction of the yoke 4 in order to minimize the number of screws 27, and the extension piece 31c is bent or curved to allow the positioning of the screw hole 4c1.

[0038] The Hall-effect IC 42, located at the distal end of the extension 31c, is welded or soldered to predetermined points on the terminals 38 in the base 31, so that the Hall-effect IC 42 is connected to the driver-control IC 41 via the terminals 38. The Hall-effect IC 42 senses the rotational position of the drive-side rotating body 24a and thus also of the rotating shaft 10, which rotates together with the drive-side rotating body 24a, based on a change in the magnetic field of the sensor magnet 24b, which rotates along with the drive-side rotating body 24a. A rotation measurement signal, indicating the sensed rotational position of the rotating shaft 10, is output by the Hall-effect IC 42 to the driver-control IC 41.

[0039] The driver control IC 41 senses the rotational position of the rotating shaft 10 and thus also the operating position (e.g., an open position and a closed position and / or an intermediate position between them) of the window pane and / or senses the rotational speed of the rotating shaft 10 and thus also the movement speed (e.g., the opening speed and / or closing speed of the window pane) based on the rotation measurement signal supplied by the Hall IC 42. Based on these measurement signals, the driver control IC 41 performs the PWM control operation of the motor 1 (of the motor body 2) and also the pinch-limit control operation to limit the object from being pinched by the window pane.

[0040] A heat sink 43 is fixed to a base surface (the side of the cover 26) of the driver-control IC 41. The heat sink 43 is made of a metal material and is designed in the form of a rectangular plate that is slightly smaller than the control IC 41. The heat sink 43 is positioned slightly away from the cover 26. The heat sink 43 effectively absorbs the heat released by the control IC 41 when the motor 1 is driven, i.e., when the driver-control IC 41 is driven, in order to cool the control IC 41.

[0041] The control circuit section 25, which includes the driver control IC 41, is installed on the mounting pieces 7f in the circuit mounting section 7d of the brush holder 7, and the contacts 37 are connected to the contacts 12a of the brush holder 7. The cover 26 is then installed on the circuit mounting section 7d. The motor body 2 and the speed reduction device 3 are assembled in such a way that the brush holder 7 is clamped between the motor body 2 and the speed reduction device 3, thus assembling the motor 1.

[0042] Next, the advantages of the present embodiment will be described. (1) In the control circuit section 25, which includes the driver control IC 41 that controls the motor 1, the terminals 38, which electrically connect the driver control IC 41 to the brush holder 7, are held in the base 31 of the control circuit section 25. The base 31 is installed on the mounting pieces 7f of the brush holder 7 in such a way that the entire control circuit section 25 is held by the brush holder 7. In this state, with the base 31 of the control circuit section 25 held by the brush holder 7, the motor body 2 and the gearbox housing 21 are assembled to form the motor 1.In the motor 1 of the present embodiment, the base 31 of the control circuit part 25 is held by the brush holder 7 separately from the electrical connection (the contacts 37, 12a) which establishes an electrical connection between the terminals 38 of the control circuit part 25 and the brush holder 7. This reduces the mechanical stress applied to the electrical connection between the terminals 38 of the control circuit part 25 and the brush holder 7. Furthermore, the control circuit part 25 is stably supported by the brush holder 7. This reduces the mechanical stress acting on the electrical connection between the driver control IC 41 (the line contacts 41b) and the terminals 38. In this way, the occurrence of electrical connection failures is minimized. (2) The control circuit part 25 is positioned between the brush holder 7 and the gearbox housing 21, for which there is a greater degree of freedom with regard to the design of its shape. It is therefore relatively easy to position the control circuit part 25 between the brush holder 7 and the gearbox housing 21. (3) The control circuit part 235 is received in the circuit mounting section 7d, which is provided in the brush holder 7. The base 31 of the control circuit part 25 is held by the brush holder 7 in the circuit mounting section 7d of the brush holder 7. With this design, the control circuit part 25 can be adequately protected. (4) The terminals 38 are embedded or recessed into the base 31 by insertion and are held in position by the base 31 of the control circuit part 25. Therefore, at the time of assembly, it is not necessary to install the terminals 38 on the base 31, nor is it necessary to provide a suitable installation location for the terminals 38. (5) The Hall IC 42, which serves as a rotary sensor, is held in position by the base 31 of the control circuit section 25. Therefore, it is not necessary to provide a separate device for holding the Hall IC 42. (6) The extension piece 31c of the base 31, which holds the Hall IC 42 at its distal end, is designed to be bent or curved to bypass the screw 27 (the screw hole 4c1) used when assembling the motor body 2 and the gearbox housing 21. More specifically, the extension piece 31c is bent or curved to place the screw 27 (the screw hole 4c1) closer to the center in the width direction of the yoke 4, so that the motor 2 and the gearbox housing 21 can be effectively assembled using the screws 27. (7) The heat sink 43, which serves as a heat dissipation element, is integrated into the driver control IC 41 of the control circuit section 25. Thus, the heat generated by the driver control IC 41 is effectively dissipated via the heat sink 43, thereby improving the cooling effect for the driver control IC. (8) The heat sink 43 of the driver control IC 41 is spaced apart from the opposite part (the cover 26 in the present embodiment) which faces the heat sink 43. Thus, the heat can be effectively dissipated from the heat sink 43. (Second embodiment)

[0043] A motor for an electric vehicle window operation system according to a second embodiment of the present invention is now described with reference to the accompanying drawings.

[0044] As in Fig. As shown in Figure 4, the motor 101 of the present embodiment comprises a motor housing 102 and a speed reduction device (a speed reduction mechanism) 103. The motor housing 102 rotates when it is excited. The speed reduction device 103 reduces the rotational speed generated by the motor housing 102 and outputs a rotation at a reduced speed.

[0045] As in the Fig. 4 and Fig. As shown in Figure 5, the main motor body 102 contains a yoke housing (hereinafter referred to simply as a yoke) 104, two permanent magnets 105 ( Fig. 5), an armature 106, a brush holder 107, and two energy supply brushes 108. The yoke 104 is shaped in a generally flattened, cup-shaped form with a closed bottom. The magnets 105 are separately attached to an inner circumferential surface of the yoke 104. The armature 106 is rotatably mounted in the yoke 104.

[0046] The brush holder 107 is made of a resin material and comprises, either as a single unit or as a whole, a holder main body 107a, a flange 107b, an extension 107c, a connector 107d and a mounting section 107e.

[0047] The holder body 107a is configured to fit essentially within an opening of the yoke 104. A bearing 109 is attached to a central hole of the holder body 107a to rotatably hold a distal end of a rotating shaft 110 of the armature 106. The distal end of the rotating shaft 110 projects outward from the yoke 104, and a sensor magnet 110a is attached to the projecting distal end of the rotating shaft 110 via a metal plate. The current-supply brushes 108 are slidably held by the holder body 107a on an inner surface of the yoke 104 of the holder body 107a in such a way that the current-supply brushes 108 are pressed radially inward against a commutator 111, which is attached to the rotating shaft 110, to establish an electrical contact between them.

[0048] The flange 107b extends radially outwards from the main holder body 107a in a direction away from the rotating shaft 110. The extension 107c projects outwards in a direction parallel to a flat surface 104a (a surface parallel to a plane of Fig. 4 or Fig. 5) of yoke 104, namely from one end (the right end in Fig. 4 or in Fig. 5) of the flange 107b, and a connector 107d is formed at a distal end of the extension 107c. The connector or plug 107d is configured to engage with an external connector or plug (not shown) in a direction perpendicular to the flat surface 104a (from the other side of the plane of Fig. 4 or Fig. 5 in the direction perpendicular to the plane of Fig. 4 or Fig. 5) The support section 107e extends from the extension 107c in the axial direction, which runs parallel to the rotating shaft 110.

[0049] A multitude of brush-side terminals 112 and a multitude of connector-side terminals 113 are recessed or embedded in the brush holder 107 by insert forming. The brush-side terminals 112 extend from a section of the holder main body 107a located within the interior of the yoke 104. The current or energy supply brushes 108 are electrically connected to the base ends of the terminals 112 by stranded wires. The connector-side terminals 113 extend from the connector 107d to the extension 107c. The external connector contacts 113a are formed at the base ends of the terminals 113 in the connector 107d. When the external connector or plug engages with the connector or plug 107d, the external connection contacts 113a are electrically connected to the terminals of the external connector.

[0050] Each of the distal ends of the brush-side terminals 112 and the connector-side terminals 113 protrudes (i.e., is exposed) in the form of an internal connecting contact 113 from the mounting section 107e in the axial direction (in Fig. 5 in the downward direction) of the motor main body 102. The internal connecting contacts 114 extend parallel in the direction perpendicular to the planar surface 104a (in the direction perpendicular to the plane of Fig. 5). In Fig. Figure 5 shows only one of the internal connection contacts 114, since the internal connection contacts 114 run parallel to each other and one after the other in the direction perpendicular to the plane of Fig. 5 are arranged.

[0051] In the brush holder 107, the flange 107b, the extension 107c and the connector 107d are essentially covered with a sealing part 115 made of an elastomer, except for sections corresponding to the external connection contacts 113a of the connector 107d.

[0052] The speed reduction device 103 includes a gearbox housing 121, a worm shaft 122, a worm wheel 123 and a coupling 124. The worm shaft 122 and the worm wheel 123 form the speed reduction mechanism.

[0053] The gearbox housing 121 is made of a resin material and includes a fixing section 121a, a worm gear receiving section 121b, a gear receiving section 121c, and a shift receiving section 121d. The fixing section 121a is formed in a shape corresponding to a flange 104b formed in the opening of the yoke 104 and is fastened to the flange 104b by means of screws 127, so that the flange 107b of the brush holder 107 is clamped or clamped between the fixing section 121a and the flange 104b via the sealing part 115.

[0054] The worm gear receiving section 121b is designed as a tubular body extending along an imaginary continuation line of the rotating shaft 110. The worm gear receiving section 121b rotatably holds the worm shaft 122 within it. The coupling 124 is provided on the side of the motor main body 102 on an interior of the worm gear receiving section 121b to establish a coupling between the worm shaft 122 and the rotating shaft 110 in such a way as to allow the transmission of a drive force between them. More specifically, when the drive force is transmitted from the rotating shaft 110 to the coupling 124, the coupling 124 transmits the drive force from the rotating shaft 110 to the worm shaft 122.Conversely, when a drive force is transmitted from the worm shaft 122 to the clutch 124, the clutch blocks the rotation of the worm shaft 122 to limit the transmission of the drive force from the worm shaft 122 to the rotating shaft 110. That is, the clutch 124 is designed to limit the rotation of the motor 101 that would be caused by the force applied from a load side (e.g., a load applied downwards to a window pane not shown) by the electric window operating system. In this way, unintentional opening movement of the window pane is advantageously limited.

[0055] The wheel mounting section 121c is designed as a circular, disc-shaped body extending in a direction perpendicular to the worm mounting section 121b. The wheel mounting section 121c rotatably holds the worm wheel 123 within it. A flat surface 121g of the wheel mounting section 121c extends continuously from the flat surface 104a of the yoke 104. The gear housing 121 and the yoke 104 are designed to have a low profile in order to achieve a low profile for the entire motor 101. An interior of the worm mounting section 121b and an interior of the wheel mounting section 121c are connected to each other at a junction where the worm shaft 122 and the worm wheel 123 mesh. An output shaft 123a is connected to the worm wheel 123 at one end and to a window regulator (not shown) at the other end.When the main motor body 102 is controlled and thereby set in rotation by the control circuit part 125, the output shaft 123a is set in rotation via the worm shaft 122 and the worm wheel 123 to drive the window regulator, so that the window pane is raised or lowered by the window regulator.

[0056] The circuit mounting section 121d is provided on the opposite side of the worm mounting section 121b, which is opposite the wheel mounting section 121c. A receiving recess 121e is formed within the circuit receiving section 121d to receive the control circuit part 125, which is installed on the brush holder 107, in the axial direction of the rotating shaft 110. More specifically, the opening of the circuit receiving section 121d (the receiving recess 121e) is located on the side of the motor main body 102 (the side of the brush holder 107) of the circuit receiving section 121d (the receiving recess 121e), and the other axial side of the circuit receiving section 121d (the receiving recess 121e) is opposite the opening of the circuit receiving section 121d (the receiving recess 121e), which opening is closed.

[0057] As in Fig. As shown in Figure 6, guide grooves 121f are designed to extend axially in the opposing inner surfaces from the circuit receiving section 121d (the receiving recess 121e) to guide the lateral edges or margins of a base 131 of the control circuit part 125. The guide grooves 121f guide the lateral edges of the base 131 of the control circuit part 125, thus limiting the movement of the control circuit part 125 in the circuit receiving section 121d, even when shocks or vibrations are applied to the motor 101 from the outside.

[0058] The control circuit section 125 will now be described in more detail. As in Fig. As shown in Figure 5, the control circuit part 125 contains a driver control IC 132 and a Hall IC 133, which are provided at the base 131 of the control circuit part 125.

[0059] The base 131 is made of a resin material and is generally plate-shaped. The base 131 includes a buttress section 131c that abuts axially against a contact surface 107f provided in the mounting section 107e of the brush holder 107. An installation projection 131d is formed in the base 131 at a location adjacent to the buttress section 131c. The installation projection 131d engages with an installation recess 107g of the mounting section 107e to hold the base 131 in position, i.e., to hold the control circuit part 125 in such a way that the buttress section 131c is abutted against or held in contact with the contact surface 107f.

[0060] The driver-control IC 132 is installed on a mounting surface 131a of the base 131, which is provided on a worm shaft 122 within the base 131. The driver-control IC 132 comprises an IC body 132a and a plurality of line contacts 132b. The IC body 132a is designed as a generally rectangular plate shape. The line or terminal contacts 132b extend outwards from the IC body 132a along a plane in the longitudinal direction of the IC body 132a. The IC body 132a contains a driver circuit and a control circuit, which are designed as a single chip or as multiple chips encapsulated in resin. The driver circuit includes, for example, a power MOSFET that supplies an electrical driver current to the motor body 102.The control circuit performs, for example, the PWM control operation and an anti-pinch control operation to limit the pinching of an object by the window pane. The lead contacts 132b are connected to the circuits of the IC body 132a. Terminals 134 are recessed, i.e., embedded by insert forming the base 131, and the lead contacts 132b are welded or soldered to predetermined portions of the terminals 134. The driver control IC 132, the electrical contacts 134a, each of which forms part of a corresponding terminal 134, protrude (are exposed) from the opposite face of the base 131, which is opposite the mounting surface 131a of the base 131, to make contact with the brush holder 107. The electrical contacts 134a are welded or soldered to the internal connection contacts 114, which extend from the brush holder 107.

[0061] Furthermore, an extension 131b, which extends to a point adjacent to the sensor magnet 110a, fixed to the rotating shaft 110, is formed in the base 131. The Hall-effect IC 133 is mounted at the distal end of the extension 131b. The Hall-effect IC 133 is welded to predetermined locations on the terminals 134 of the base 131 and is connected to the driver-control IC 132 via the terminals 134. The Hall-effect IC 133 detects the rotational position of the rotating shaft 110 based on a change in the magnetic field of the sensor magnet 110a, which rotates together with the rotating shaft 110. The Hall-effect IC 133 outputs a rotation signal, which indicates the perceived rotational position of the rotating shaft 110, to the driver-control IC 132.

[0062] The driver control IC 132 senses the rotational position of the rotating shaft 110 and thus an operating position (e.g., an open position and a closed position and / or an intermediate position between them) of the window pane and / or the rotational speed of the rotating shaft 110 and thus also the movement speed (e.g., the opening speed and / or the closing speed) of the window pane, based on the rotation measurement signal supplied by the Hall IC 133. Based on these measurement signals, the driver control IC 132 performs a PWM control operation of the motor 101 (of the motor body 102) and also performs an anti-pinch control operation to limit the object from being pinched by the window pane.

[0063] A heat sink 135 is attached to a side surface of the driver-control IC 132. The heat sink 135 is made of a metal material and is designed as a rectangular plate that is slightly smaller than the control IC 132. The heat sink 135 efficiently absorbs and dissipates the heat generated by the control IC 132 when the motor 101 is driven, i.e., when the driver-control IC 132 is driven, in order to cool the driver-control IC 132.

[0064] The control circuit section 125, which includes the driver control IC 132, is installed such that the installation projection 131d of the base 131 is installed on the mounting section 107e of the brush holder 107, and that the connecting contacts 134a of the terminals 134 are connected to the internal connecting contacts 114 on the side of the brush holder 107. The motor body 102 and the speed reduction device 103 are then assembled such that the control circuit section 125 is received in the circuit receiving section 121d of the gearbox housing 121.

[0065] Next, the advantages of the present embodiment will be described. (1) In the control circuit section 125, which contains the driver control IC 132 that controls the motor 101, the terminals 134, which establish an electrical connection between the driver control IC 132 and the brush holder 107, are held in the base 131 of the control circuit section 125. The base 131 is installed on the mounting section 107e of the brush holder 107, so that the entire control circuit section 125 is held by the brush holder 107. In this state, with the base 131 of the control circuit section 125 held by the brush holder 107, the motor body 102 and the gearbox housing 121 are assembled to form the motor 101.In the motor 101 of the present embodiment, the base 131 of the control circuit part 125 is held by the brush holder 107 separately from the electrical connection (the contacts 134a and the internal connection contacts 114), which electrically establishes a connection between the terminals 134 of the control circuit part 125 and the brush holder 107. This reduces the mechanical stress applied to the electrical connection between the terminals 134 of the control circuit part 125 and the brush holder 107. Furthermore, the control circuit part 125 is held securely by the brush holder 107. This reduces the mechanical stress on the electrical connection between the driver control IC 132 (the line contacts 132b) and the terminals 134. In this way, the risk of electrical connection failure is minimized. (2) The control circuit part 125 is positioned between the brush holder 107 and the gearbox housing 121, which allows for a high degree of freedom in terms of its design shape. It is therefore relatively easy to position the control circuit part 125 between the brush holder 107 and the gearbox housing 121. (3) The control circuit part 125 is received in the circuit mounting section 121d, which is provided in the gearbox housing 121. The base 131 of the control circuit part 125 is held by the brush holder 107 in the circuit mounting section 121d of the gearbox housing 121. In this design, the control circuit part 125 can be adequately protected. (4) The terminals 134 are embedded in the base 131 of the control circuit part 125, i.e., they are embedded in it by means of a molded insert and are thereby held in position. Therefore, it is not necessary to install the terminals 134 on the base 131 at the time of assembly, and consequently, it is also not necessary to provide a corresponding installation point for installing the terminals 134. (5) The Hall IC 133, which serves as a rotation sensor, is held in position by the base 131 of the control circuit section 125. This means that it is not necessary to provide a separate device for holding the Hall IC 133. (6) The heat sink 135, which serves as a heat dissipation element, is provided in conjunction with the driver control IC 132 of the control circuit section 125. Thus, the heat generated by the driver control IC 132 is effectively dissipated via the heat sink 135, thereby improving the cooling effect for the driver control IC 132.

[0066] The embodiments described above can be modified in the following way.

[0067] In the first embodiment, the cover 26, which closes the opening of the circuit mounting section 7d that accommodates the control circuit part 25, is made of a metal material. Alternatively, the cover 26 can also be made of a resin material.

[0068] In the first embodiment, four mounting pieces 7f are provided on the brush holder 7, serving as a mounting device for holding the base 31 of the control circuit part 25. In the second embodiment, the brush holder 107 includes a mounting section 107e (primarily the mounting recess 107g, which engages with the mounting projection 131d of the base 131) which serves as a mounting device for holding the base 131 of the circuit control part 125. The mounting device for holding the control circuit part (the base) is not limited to those described above, and, for example, the shape, number, and position of the mounting device (or mounting elements) can be modified in any suitable way. In such a case, the shape of at least one of the features of the base and the brush holder can be modified to form the mounting device.

[0069] In each of the embodiments described above, the terminals 38, 134 are embedded or recessed in the base 31, 131, or contained therein by insertion by the control circuit part 25, 125. Alternatively, the terminals can also be installed on the surface of the base or attached to it.

[0070] In each of the embodiments described above, the Hall-effect IC 42, 133, which serves as a rotation sensor, is held in conjunction with the base 31, 131. Alternatively, the rotation sensor, such as the Hall-effect IC, can be held by a mounting element that is separate from the base.

[0071] In each of the embodiments described above, the heat sink 43, 135 is integrated with the driver control IC 41, 132. Alternatively, the heat sink can be provided separately from the driver control IC. Furthermore, if cooling of the driver control IC 41, 132 can be achieved without the heat sink 43, 135, the heat sink 43, 135 can also be omitted.

[0072] In each of the embodiments described above, the present invention is implemented in the form of the motor 1, 101 of the electric window actuation system. Alternatively, the subject matter of the present invention can also be implemented in a motor of a sunroof system, a sliding door system, a tailgate system, or any other suitable system or device in a vehicle.

[0073] Additional advantages and modifications are immediately apparent to those skilled in the art. Therefore, the invention is not limited in the broadest sense to the specific details, the representative device, and the illustrated examples that have been presented and described.

Claims

Motor, comprising: a motor body (2) containing a brush holder (7) which holds a plurality of power supply brushes (8, 108); and a gear housing (21) which accommodates a speed reduction mechanism which reduces the rotational speed generated by the motor body (2) and outputs a reduced-speed rotation; a control circuit part (25) comprising: a driver control IC (41) which controls the rotation of the motor body (2); and a base (31) which holds a plurality of terminals (38) which electrically connect the driver control IC (41) to the plurality of power supply brushes (8, 108) of the brush holder (7), the base (31) holding the brush holder (7); and a rotation sensor (21cc) which detects the rotation of the motor body (2), the rotation sensor (21cc) being held by the base (31);and wherein the base (31) includes an extension (31c) which holds the rotation sensor (21c) at a distal end thereof; and wherein the extension (31c) is curved to bypass a screw (27) which is used to connect the main motor body (2) to the gearbox housing (21). Motor according to claim 1, wherein the control circuit part (25) is positioned between the brush holder (7) and the gearbox housing (21). Motor according to claim 1 or 2, wherein: the brush holder (7) includes a receiving section (7d) which is integrally formed with or integrally formed with the brush holder (7) and receives the control circuit part (25); and wherein the base (31) of the control circuit part (25) is held by the brush holder (7) in the receiving section (7d) of the brush holder (7). Motor according to one of claims 1 to 3, wherein the base (31) is made of a resin material; and the plurality of connections (38) is embedded or embedded in the base (31). Motor according to one of claims 1 to 4, further comprising a heat dissipation element (43) which is provided in conjunction with the driver control IC (41). Motor according to claim 5, in which the heat dissipation part (43), which is provided in conjunction with the driver control IC (41), is spaced apart from an opposing part (26), which is arranged opposite the heat dissipation part (43). Motor according to claim 1, wherein the base (31) of the control circuit part (25) is attached to the brush holder (7) by a snap connection. Motor according to claim 7, wherein: the brush holder (7) comprises a plurality of installation pieces (7f) extending in a direction generally parallel to the axis of rotation of the motor body (2); and the base (31) of the control circuit part (25) is connected by a snap connection to the plurality of installation pieces (7f) in a direction generally parallel to the axis of rotation of the motor body (2). Motor according to claim 8, wherein each of the installation pieces (7f) is formed as a deformable cantilever strut having a hook (7fa) at a distal free end thereof to engage a surface of the base (31) of the control circuit part (25) in order to hold the base (31) of the control circuit part (25). Motor according to claim 1, wherein the base of the control circuit part (25) is detachably attached to the brush holder (7). Motor according to claim 1, comprising the motor body (2) and the gearbox housing (21) being assembled in a state in which the base (31) is supported or held by the brush holder (7). A method for manufacturing a motor, comprising the following steps: Installing a base (31) of a control circuit part (25), which holds a plurality of terminals (38) in position on a brush holder (7) of a motor body (2), which holds a plurality of power supply brushes (8, 108) in position, such that the base (31) of the control circuit part (25) is held by the brush holder (7), and wherein a driver control IC (41) of the control circuit part (25), which controls the rotation of the motor body (2), is electrically connected to the brush holder (7) via the plurality of terminals (38); and wherein an extension (31c) of the base (31), which holds a rotation sensor (21c) for detecting the rotation of the motor body (2) at a distal end thereof, is curved to bypass a screw (27);and assembling the motor body (2), which includes the brush holder (7), with a gearbox (21), which accommodates a speed reduction mechanism that reduces the rotational speed generated by the motor body (2) and outputs a rotation at a reduced speed, after installing the base (31) of the control circuit part (25) on the brush holder (7); and connecting the motor body (2) and the gearbox (21) by means of the screw (27). Manufacturing method according to claim 12, wherein installing the base (31) of the control circuit part (25) comprises: installing the control circuit part (25) on the brush holder (7) of the motor main body (2) in a direction generally parallel to an axis of rotation of the motor main body (2); and snap-fastening the base (31) of the control circuit part (25) to a plurality of mounting parts of the brush holder (7). Manufacturing method according to claim 12, wherein the installation of the base (31) of the control circuit part (25) comprises the removable fixing of the control circuit part (25) to the brush holder (7).

Images