Motor

Abstract

Engine (1), comprising: a motor unit (2) containing a rotating shaft (13) and a power connection (34); a gear housing (41) coupled to the motor unit (2), the gear housing (41) housing a deceleration mechanism (42) that decelerates and outputs rotation of the rotary shaft (13); a connector module (4) including a connector terminal (55, 71, 81) connected to the power terminal (34), a circuit substrate connected to the connector terminal (55, 71, 81), and a connector housing (51) coupled to the gear housing (41), wherein the connector terminal (55, 71, 81) and the circuit substrate are fixed to the connector housing (51), wherein the power connection (34) is inserted into a socket of the connector connection (55, 71, 81) and connected thereto when coupling the connector housing (51) to the gear housing (41) in a coupling direction (X), the connector terminal (55, 71, 81) includes a rigid portion fixed to the connector housing (51), a substrate connecting portion (73, 83) connected to the circular substrate, and a supported portion (74, 84) located closer to the socket in the coupling direction (X) than the substrate connecting portion (73, 83), wherein the rigid portion is arranged closer to the socket in the coupling direction (X) than the substrate connecting portion (73, 83), and the supported portion (74, 84) is arranged closer to the socket in the coupling direction (X) than the rigid portion, and the connector housing (51) includes a terminal support portion (91, 92) supporting the supported portion (74, 84) from a rear side in the coupling direction (X) such that the supported portion (74, 84) is disposed between the terminal support portion (91, 92) and the socket.

Description

[0001] The present invention relates to a motor for use as a drive source for an electric window lifting device.

[0002] PCT International Publication No. WO 2011 / 107300 A1 discloses a motor including a motor unit having a rotating shaft, a gear case coupled to the motor unit, and a connector module having a connector housing coupled to the gear case. The gear case houses a deceleration mechanism that decelerates the rotation of the rotating shaft and outputs it. The connector housing supports a connector terminal connected to a power terminal of the motor unit and a circuit substrate connected to the connector terminal. The power terminal is inserted into and connected to a socket of the connector terminal when the connector housing is coupled to the gear case. This structure enables the connection of the connector terminal and the power terminal of the motor unit to be completed when the connector housing is coupled to the gear case.Therefore, the manufacturing process is simplified.

[0003] However, in the above motor, a large contact load is generated when the power terminal of the motor unit is inserted into the socket of the connector terminal. This load may be exerted on the section where the connector terminal and the circuit substrate are connected. This may cause a connection failure between the connector terminal and the circuit substrate.

[0004] Further prior art documents cited are DE 10 2007 058 348 A1 and DE 10 2010 002 511 A1.

[0005] The object of the present invention is to provide a motor that suppresses connection errors of the connector terminal and the circuit substrate caused by the contact load generated when connecting the terminals.

[0006] One aspect of the present invention is a motor provided with a motor unit including a rotating shaft and a power source. A gear case is coupled to the motor unit. The gear case houses a deceleration mechanism that decelerates and outputs rotation of the rotating shaft. A connector module includes a connector terminal connected to the power terminal, a circuit substrate connected to the connector terminal, and a connector housing coupled to the gear case. The connector terminal and the circuit substrate are attached to the connector housing. The power terminal is inserted into and connected to a socket of the connector terminal when the connector housing is coupled to the gear case in a coupling direction.The connector terminal includes a rigid portion fixed to the connector housing, a substrate connection portion connected to the circuit substrate, and a supported portion located closer to the receptacle than the substrate connection portion. The connector housing includes a terminal support portion that supports the supported portion from a rear side in the mating direction.

[0007] Other aspects and advantages of the present invention will become apparent from the following description, taken in conjunction with the accompanying drawings, which illustrate by way of example the principles of the invention.

[0008] The invention, together with objects and advantages thereof, will best be understood by reference to the following description of presently preferred embodiments together with the accompanying drawings. Fig. 1 is a front view showing an embodiment of an engine; Fig. 2 a top view of a motor unit and a connector module of Fig. 1 from a gearbox housing; Fig. 3 a side view of the connector module used in Fig. 1, in the planar direction of the motor; Fig. 4 a rear view of the connector module, which in Fig. 1 is shown, in the direction of strength of the motor; Fig. 5 is a rear view showing a portion of the connector module without a control circuit substrate; Fig. 5A is an enlarged view of the circled portion shown in Fig. 5 is shown; Fig. 6 is a schematic view illustrating a connector terminal; and Fig. 7 is a side view of a connector module in another example from the planar direction of the motor.

[0009] An embodiment of a motor is described below.

[0010] The engine 1 of the present embodiment shown in Fig. 1 is used as a drive source for an electric window regulator device that electrically raises and lowers a window pane of a vehicle. The motor 1 includes a motor unit 2 mounted in the upper portion of Fig. 1, a deceleration unit 3 arranged on an output side (lower side) of the motor unit 2, and a connector module 4 connected to one side (left side when viewed in Fig. 1) of the deceleration unit. The motor 1 as a whole has a relatively thin profile in one direction (perpendicular to the plane of Fig. 1) which is perpendicular to the axis of the motor unit 2 (axis L1 of the rotary shaft 13). When viewed in the axial direction of the motor 1, the longitudinal direction (from left to right in Fig. 1) is called the planar direction and the direction that runs along the short side (perpendicular to the plane of Fig. 1 direction) is called the strength direction. Therefore, the axial direction, the planar direction, and the strength direction of the motor 1 are directions that are perpendicular to each other. [Structure of the motor unit]

[0011] The yoke housing 11 (hereinafter simply referred to as yoke 11) of the motor unit 2 is tubular and has a closed non-output end (upper end in Fig. 1). An output end 11a is in the axial direction (lower side in Fig. 1) of the motor 1, and a flange 11b extends toward a radially outer side of the output end 11a. Magnets (not shown) are fixed to an inner peripheral surface of the yoke 11, and an armature 12 is arranged on the inside of the magnets.

[0012] The armature 12 includes a cylindrical rotary shaft 13 arranged at a central position in the radial direction of the yoke 11, an armature core 14 fixed to the rotary shaft 13 and rotating integrally therewith, coils 15 wound around the armature core 14, and a commutator 16 fixed to the rotary shaft 13 closer to the distal end (closer to the lower end in Fig. 1) as the armature core 14 is attached.

[0013] A base end (top end in Fig. 1) The rotating shaft 13 is axially supported by a bearing (not shown) located at the lower central portion of the yoke 14. A distal end of the rotating shaft 13 protrudes from the yoke 11 through the opening in the output end 11a of the yoke 11. The armature core 14 is fixed to the rotating shaft 13 in the yoke 11 and radially faces the magnet (not shown).

[0014] The commutator 16 is externally fitted and fixed to the portion of the rotating shaft 13 that protrudes from the yoke 11. The commutator 16 is therefore arranged outside the yoke 11 and rotates integrally with the rotating shaft 13. The commutator 16 is cylindrical and includes a plurality of segments 16a arranged side by side along the outer peripheral surface of the commutator 16 and spaced apart from each other in the circumferential direction. Some or all of the segments 16a are electrically connected to the coils 15. In other words, current can be supplied to the coils 15 via the segments 16a of the commutator 16.

[0015] As in Fig. As shown in Figure 2, the motor unit 2 includes a resin brush holder 21 at the output end 11a of the yoke 11. The brush holder 21 has a plate-shaped base 22 located outside the output end 11a of the yoke 11. The size of the base 22 in the direction perpendicular to the axis is slightly larger than the opening of the output end 11a. A sealing member 23, which ensures a liquid-tight seal between a gear housing 31 of the deceleration unit 3, which will be described later, and the yoke 11, is arranged on the outer edge of the base 22. The sealing member 23 is made of, for example, elastomer.

[0016] A commutator receiving portion 24, which protrudes in a direction opposite to the yoke 11 along the axial direction, is formed integrally with the base 22 at the central portion of the base 22. The commutator 16 is disposed within the commutator receiving portion 24. Therefore, the commutator receiving portion 24 covers the outer periphery of the commutator 16 and the end surface of the commutator 16 on the side opposite (closer to the gear housing 41) to the yoke 11 in the axial direction. The rotary shaft 13 is formed such that the distal end protrudes from the commutator receiving portion 24.

[0017] Two brush receiving portions 25 extending toward the radially outer side are integrally formed with the commutator receiving portion 24. The two brush receiving portions 25 are arranged to be line-symmetrical with an imaginary line L2. The imaginary line L2 is parallel to the planar direction of the motor 1 and perpendicular to the axis L1 of the rotating shaft 13. Each brush receiving portion 25 is further incorporated into the base 22. Each brush receiving portion 25 communicates with the interior of the commutator receiving portion 24. A current brush 26 is received within each brush receiving portion 25 so as to be movable in the radial direction. A distal end (radially inner end) of the current brush 26 is configured to contact the outer peripheral surface of the commutator 16 in the commutator receiving portion 24.The commutator receiving portion 24 reduces the scattering of brush powder generated when the current brush 26 is scraped due to the sliding of the commutator 16.

[0018] Two support rods 31, which protrude from the base 22 in the axial direction opposite to the yoke 11 (toward the gear case 41), are formed between the two brush receiving portions 25 in the circumferential direction. In the same manner as the brush receiving portions 25, the two support rods 31 are formed to be line-symmetrical with respect to the imaginary line L2. Each support rod 31 has a circular cross-section, and a coil portion of a torsion spring 32 is externally inserted and held by each support rod 31. The torsion spring 32 biases the current brush 26 toward the radially inner side (i.e., toward the commutator 16). Each support rod 31 operates to contact the gear case 41 in the axial direction and the radial direction, and enables positioning in the axial direction and the radial direction with respect to the gear case 41.

[0019] In the brush holder 21, two choke coils 33 and two power terminals 34 are arranged on opposite sides in the planar direction with respect to the position where the brush receiving portions 25 and the support rods 31 are arranged. The choke coils 33 and the power terminals 34 are formed to be line-symmetrical with respect to the imaginary line L2. Each power terminal 34 is electrically connected to the corresponding power brush 26 through the choke coil 33. The choke coil 33 is a noise reduction element that removes noise from the power supplied to the armature 12. The power terminal 34 is formed from a single metal sheet and includes an insertion portion 34a connected to the connector terminals 71, 82, which will be described later. The insertion portion 34a has a thin profile and is parallel to the planar surface (plane perpendicular to the thickness direction) of the motor 1. [Structure of the slowdown unit]

[0020] As in Fig. 1, the deceleration unit 3 includes the gear case 41 and a deceleration mechanism 42 accommodated in the gear case 41. The gear case 41 includes a holder receiving portion 43 fixed to the flange 11b of the yoke 11, a worm shaft receiving portion 44 extending in a direction opposite to the yoke 11 along the direction of the axis L1 of the rotary shaft 13 from the holder receiving portion 43, and a gear receiving portion 45 formed to extend sideways from the worm shaft receiving portion 44 in the planar direction (right side in Fig. 1) runs.

[0021] The gear housing 41 is fixed to the yoke 11 when the holder receiving portion 43, which contacts the flange 11b from the axial direction, is fixed to the flange 11b by a plurality of bolts 46. The distal end of the rotary shaft 13 enters the interior of the holder receiving portion 43, and the commutator 16 is disposed in the holder receiving portion 43. Furthermore, portions of the brush holder 21, such as the commutator receiving portion 24, the brush receiving portion 25, each power terminal 34, and the like, protrude from the yoke 11 from the output end 11a of the yoke 11 and enter the interior of the holder receiving portion 43.

[0022] A substantially cylindrical worm shaft 47 is received in the worm shaft receiving portion 44. A threaded worm portion 47a is formed at the axially central portion of the worm shaft 47. The worm shaft 47 is coaxial with the rotary shaft 13 (formed such that their center axes coincide) and rotatably supported within the shaft receiving portion 44.

[0023] The worm shaft 47 and the rotary shaft 13 are coupled by a coupling 48 arranged in the holder receiving portion 43. The coupling 48 includes a drive-side rotary body 48a fixed to the distal end of the rotary shaft 13 and a driven-side rotary body 48b fixed to one end in an axial direction of the worm shaft 47 (upper end in Fig. 1). The driven-side rotating body 48b is coupled to the driving-side rotating body 48a and rotates integrally therewith. The clutch 48 functions to transmit the rotation of the driving-side rotating body 48a to the driven-side rotating body 48b, and not to transmit the rotational force of the driven-side rotating body 48b to the driving-side rotating body 48a. That is, the clutch 48 transmits the rotational input from the rotating shaft 13 to the worm shaft 47 and blocks the rotational input from the worm shaft 47.

[0024] An interior of the gear receiving portion 45 is connected to an interior of the worm shaft receiving portion 44. A disc-shaped worm gear 49, which meshes with the worm portion 47a, is housed in the gear receiving portion 45. The deceleration mechanism 42 includes the worm shaft 47 and the worm gear 49. The worm gear 49 is arranged such that its rotational axis L3 is parallel to the motor power direction, and it is rotatably supported by the gear receiving portion 45. The worm gear 49 is disc-shaped and thin in the direction of the axis L3. An output shaft 50 extending in the axial direction of the worm gear 49 rotates integrally with the worm gear 49 at the central portion of the worm gear 49. A distal end of the output shaft 50 protrudes from the gear case 41, and the window glass of the vehicle is coupled to the distal end of the output shaft 50 through a window regulator (not shown).

[0025] A disc-shaped sensor magnet 17 is attached to the drive-side rotating body 48a of the clutch 48. The sensor magnet 17 is coaxial with the axis L1 of the rotating shaft 13 and has a rectangular cross-section in the radial direction. The sensor magnet 17 is designed to be rotatable integrally with the rotating shaft 13 and the drive-side rotating body 48a. [Connector unit structure]

[0026] The bracket receiving portion 43 includes a connector attachment portion 43a extending toward one side (opposite the direction of the wheel receiving portion 45) in the planar direction. The connector module 4 is attached to the connector attachment portion 43a. The connector module 4 protrudes from the center of the motor 1 (axis L1 of the rotary shaft 13) toward one side (opposite the direction of extension of the wheel receiving portion 45) in the planar direction.

[0027] As in Fig. As shown in Figure 1, the connector module 4 includes a resin-made connector housing 51 coupled to the connector attachment portion 43a. A hooking piece 51a, which is hooked to a hooking portion 43b of the connector attachment portion 43a, is formed on each end surface in the motor axial direction in the connector housing 51. The connector housing 51 is fixed to the gear case 41 when each hooking piece 51a is hooked to the hooking portion 43b. Furthermore, when coupling the connector module 4, the connector housing 51 is coupled along the planar direction (coupling direction X) of the motor 1 with respect to the connector attachment portion 43.

[0028] As in Fig. As shown in Figure 2, the connector housing 51 includes an opening 51b opening toward the transmission housing 41. The connector mounting portion 43a includes an opening (not shown) opening toward the connector module 4 corresponding to the opening 51b, and the edges of both openings are in contact with each other through a sealing member 52. This seals the gap between the opening 51b of the connector housing 51 and the opening of the transmission housing 41. An end surface of the opening 51b of the connector housing 51 is inclined with respect to the motor power direction. In other words, an interface between the connector mounting portion 43a and the connector housing 51 is inclined with respect to the motor power direction.

[0029] On a side surface in the thickness direction of the connector housing 51, an external connection unit 53 is formed for expansion in the thickness direction. As shown in Fig. 1, an insertion hole 53a extending toward the interior of the connector housing 51 is recessed on the external connection unit 53. The insertion hole 53a is recessed in the thickness direction, and the inner surface defining the insertion hole 53a has a shape corresponding to an external shape of an external connector (not shown) for insertion into the insertion hole 53a. The periphery of the external connection unit 53 is surrounded by a substantially cylindrical connector boot 54. The connector boot 54 is a member for preventing water from entering the insertion hole 53a. The connector boot 54 of the present embodiment is made of elastomer and integrally molded onto the connector housing 51.

[0030] As in Fig. As shown in Figure 2, a plate-shaped control circuit substrate 61 is attached to the connector housing 51. The connector housing 51 is arranged on the control circuit substrate 61 such that a portion of the control circuit substrate 61 protrudes from the opening 51b. The connector housing 51 also includes two positioning portions 51c extending in the motor strength direction. The positioning portion 51c extends through the control circuit substrate 61, and, for example, the distal end of the positioning portion 51c is thermally deformed (thermally caulked) to fix and position the control circuit substrate 61.

[0031] The control circuit substrate 61 is arranged such that its plate surface is perpendicular to the motor power direction. In other words, the control circuit substrate 61 is arranged such that its plate surface is parallel to the flat plane of the motor 1. Thus, miniaturization in the motor power direction can be realized while maintaining the planar area of the control circuit substrate 61.

[0032] The control circuit substrate 61 is arranged between a first imaginary plane P1 and a second imaginary plane P2, which are established based on the shape (outer diameter) of the sensor magnet 17. In detail, the first imaginary plane P1 is a plane parallel to the planar motor surface (a plane perpendicular to the motor strength direction) and touching one end 17a in the motor strength direction of the sensor magnet 17. The second imaginary plane P2 is a plane parallel to the planar motor surface and touching the other end 17b in the motor strength direction of the sensor magnet 17. By disposing the control circuit substrate 61 between the first and second imaginary planes P1, P2, which are parallel to the planar motor surface, the control circuit substrate 61 is fitted within the width of the sensor magnet 17 in the motor strength direction. This miniaturizes the motor 1 in the strength direction.The insertion portion 34a of the power connector 34 is also arranged such that it is fitted between the first and second imaginary planes P1, P2.

[0033] The control circuit substrate 61 is arranged at a position (offset position) deflected in the motor strength direction with respect to the imaginary line L2, which is parallel to the planar motor direction and perpendicular to the axis L1 of the rotary shaft 13. In other words, the control circuit substrate 61 is arranged between the imaginary line L2 and one of the first and second imaginary planes P1, P2 (the second imaginary plane P2 in the present embodiment).

[0034] A portion of the control circuit substrate 61 is disposed adjacent to the external connection unit 53 in the motor power direction. The external connection unit 53 includes a terminal holding portion 53b (see Fig. 5), and a plurality of connector terminals 55, which are embedded by insert molding, are fixed to the terminal holding portion 53b. One end of each connector terminal 55 is connected to the control circuit substrate 61. The other end of each connector terminal 55 protrudes into the insertion hole 53a of the external connection unit 53 and is configured to connect to the external connector inserted into the insertion hole 53a. The input and output of electrical signals and the supply of power to the motor 1 are performed through this external connector. The resins forming the insertion hole 53a and the terminal holding portion 53b may have different colors (for example, black and white) to improve visibility when connecting the external connector. In particular, the connector boot 54 can obstruct the view of the interior of the connector housing 51 in a direction away from the plane of Fig. 1. In such a case, the profile of the terminal holding portion 53b in the insertion hole 53 stands out due to its color (white), which differs from the color of the terminal holding portion 53b. This improves visibility and facilitates connection of the external connector.

[0035] As in Fig. As shown in Fig. 3, a Hall integrated circuit 62 serving as a rotation detection element, a control circuit 63, a relay circuit 64 serving as a drive circuit, and a capacitor 65 serving as a noise reduction element are mounted on a surface 61a (plate surface on the imaginary line L2 side) of the control circuit substrate 61. The relay circuit 64 and the capacitor 65 are arranged in a space below the external connection unit 53 in the axial direction.

[0036] As in Fig. 2 and Fig. As shown in Figure 4, the control circuit substrate 61 includes an extended portion 61b located at the same position as the sensor magnet 17 in the axial direction of the motor. The extended portion 61b extends toward the sensor magnet 17 in the planar direction of the motor and includes a distal end facing the outer peripheral surface of the sensor magnet 17 in the planar direction of the motor. The Hall integrated circuit 62 is disposed on the extended portion 61b. That is, the extended portion 61b extends such that the Hall integrated circuit 62 can be disposed near the sensor magnet 17.

[0037] The Hall integrated circuit 62 is arranged at the same position as the sensor magnet 17 in the axial direction of the motor. The Hall integrated circuit 62 is mounted on the plate surface (surface 61a) on the imaginary line L2 side of the control circuit substrate 61. That is, the Hall integrated circuit 62 is arranged between the control circuit substrate 61 and the imaginary line L2, and the control circuit substrate 61 is not arranged between the Hall integrated circuit 62 and the sensor magnet 17. The Hall integrated circuit 62 is therefore arranged near the sensor magnet 17. In the present embodiment, the control circuit substrate 61 and the sensor magnet 17 have the positional relationship described above.Therefore, the surface of the Hall integrated circuit 62 mounted on the control circuit substrate 61 (the surface parallel to the surface 61a of the control circuit substrate 61) is substantially perpendicular to the rotation direction of the rotary shaft 13.

[0038] The Hall integrated circuit 62 alternately detects a first magnetic field (vertical magnetic field) entering the surface (plane parallel to the surface 61a of the control circuit substrate 61) in the vertical direction and a second magnetic field entering the surface in the horizontal direction to generate pulse signals based on the corresponding magnetic fields. The Hall integrated circuit 62 outputs the pulse signals of two phases to the control circuit 63. When the sensor magnet 17 rotates, the pulse signal obtained from the first magnetic field and the pulse signal obtained from the second magnetic field change at a phase difference of 90 degrees (electrical angle) with respect to each other. The control circuit 63 detects the rotation information (rotational position (rotation angle), rotation direction, rotation speed, etc.) of the sensor magnet 17 (i.e., the rotating shaft 13) based on the pulse signals of two phases.The control circuit 63 then controls the relay circuit 64 based on the rotation information of the rotating shaft 13 to supply drive current to the armature 12. This realizes the desired rotation of the armature 12. [Connector connection]

[0039] As in Fig. 5 and Fig. 5A, a terminal holder 56 for holding two connector terminals 71, 81 (tuning fork terminal) is provided on the side of the gear housing 41 (left side in Fig. 5) of the terminal holding portion 53b is formed in the connector housing 51. The terminal holder 56 protrudes closer to the rotary shaft 13 with respect to the end surface of the opening 51b. A press-fit portion 51d having a circular cross section, which positions the gear housing 41 with respect to the connector attachment portion 43a, is formed in the terminal holder 56 to protrude in the coupling direction X of the connector module 4.

[0040] As in Fig. 5A and Fig. As shown in FIG. 6, two press-fit recesses 57, into which the press-fit portions 72, 82 (fixed portions) of the connector terminals 71, 81 are press-fitted and fixed, are arranged side by side in the height direction of the connector module 4 (coinciding with the direction of the axis L1 of the rotary shaft 13) in the terminal holder 56. The press-fit portion 72 of one connector terminal 71 is press-fitted and fixed into the press-fit recess 57 on the upper side, and the press-fit portion 82 of the other connector terminal 81 is press-fitted and fixed into the press-fit recess 57 on the lower side. Each press-fit recess 57 is recessed in the motor strength direction.

[0041] Each connector terminal 71, 81 is formed by pressing and bending a metal sheet into a predetermined shape. Each connector terminal 71, 81 includes the press-fit portion 72, 82, a substrate connection portion 73, 83 connected to the control circuit substrate 61, a supported portion 74, 84, and a bifurcated connection portion 75, 85 (socket) at the distal end.

[0042] In detail, each connector terminal 71, 81 includes a first extended portion 76, 86 extending in the planar motor direction. The first extended portion 76, 86 extends perpendicularly to the press-fit portion 72, 82 extending along the motor strength direction. Each substrate connecting portion 73, 83 extends in the opposite direction to the fitting portion 72, 82 along the motor strength direction of each first extended portion 76, 86. Each substrate connecting portion 73, 83 extends through the control circuit substrate 61 and is connected to the back surface 61c of the control circuit substrate 61 by solder and the like (see Fig. 4 and Fig. 6). The substrate connecting portions 73, 83 are arranged in the height direction of the connector module 4.

[0043] One substrate connecting portion 73 is formed closer to the base end (position remote from the bifurcated connecting portion 75) of the first extended portion 76 with respect to the press-fit portion 72. The other substrate connecting portion 83 is formed closer to the base end (position remote from the bifurcated connecting portion 85) of the first extended portion 86 with respect to the press-fit portion 82. In other words, each press-fit portion 72, 82 is formed closer to the distal end (closer to the bifurcated connecting portion 75, 85) with respect to each substrate connecting portion 73, 83.

[0044] As in Fig. 3, Fig. 5A and Fig. 6, each connector terminal 71, 81 includes a second extended portion 77, 87. The second extended portion 77, 87 extends downward through a bent portion 79, 89 bent at right angles from the distal end of each first extended portion 76, 86. The second extended portion 77 of one connector terminal 71 extends downward and diagonally from the first extended portion 76 toward the connector sleeve 54. The second extended portion 87 of the other connector terminal 81 extends downward and along the connector height direction from the first extended portion (see Fig. 3). At least a part of the second extended portion 77 is the supported portion 74 supported by a first terminal support portion 91 formed in the connector housing 51. At least a part of the second extended portion 87 is the supported portion 84 supported by a second terminal support portion 92 formed in the connector housing 51.

[0045] As in Fig. As shown in FIG. 5A, each second extended portion 77, 87 is arranged deflected from each other in the motor planar direction. The lower end of each second extended portion 77, 87 is bent at a right angle to the gear case 51 and extends along the motor planar direction. The bifurcated connecting portion 75, 85 is formed at the distal end of each second extended portion 77, 87. That is, one connector terminal 71 is clamp-shaped and includes two bent portions 79, 78 arranged between the press-fit portion 72 and the bifurcated connecting portion 75. The other connector terminal 81 is clamp-shaped and includes two bent portions 89, 88 arranged between the press-fit portion 82 and the bifurcated connecting portion 85.The bent portion 78 at the lower end of the second extended portion 77 and the bent portion 88 at the lower end of the second extended portion 87 are formed at the same location relative to each other in the connector height direction (motor axial direction). The forked connecting portion 75 of the second extended portion 77 and the forked connecting portion 85 of the second extended portion 87 are formed at the same location relative to each other in the connector height direction (motor axial direction).

[0046] The forked connecting portions 75, 85 formed at the distal ends of the connector terminals 71, 81 are arranged in the motor strength direction. The forked connecting portion 75 of one connector terminal 71 is located on the surface 61a side, using the control circuit substrate 61 as a reference. The forked connecting portion 85 of the other connector terminal 81 extends in a bracket shape in the motor strength direction from the bent portion 88 at the lower end of the rear surface 61c of the control circuit substrate 61 and is located closer to the rear surface 61c of the control circuit substrate 61 than the forked connecting portion 75.

[0047] As in Fig. As shown in FIG. 2, the insertion portion 34a of the power terminal 34 disposed in the gear case 41 is inserted into each bifurcated connecting portion 75, 85. The bifurcated connecting portion 75, 85 sandwiches the insertion portion 34a in the motor strength direction with its elastic force, so that each connector terminal 71, 81 and each power terminal 34 are electrically connected. The control circuit substrate 61 is disposed between the bifurcated connecting portions (specifically, between the connecting portion of the bifurcated connecting portion 75 and the insertion portion 34a and the connecting portion of the bifurcated connecting portion 85 and the insertion portion 34a) when viewed from the motor axial direction.

[0048] The connector housing 51 includes the first terminal support portion 91 for supporting the supported portion 74 of one connector terminal 71 and a second terminal support portion 92 for supporting the supported portion 84 of the other connector terminal 81. The first and second terminal support portions 91, 92 are formed on the lower side of the press-fit recess 57.

[0049] The second terminal support portion 92 is arranged on the rear side in the coupling direction X of the second extended portion 87 of the connector terminal 81. In other words, the second extended portion 87 is arranged along the second terminal support portion 92 on the front side in the coupling direction X of the second terminal support portion 92. The second terminal support portion 92 contacts substantially the entire second extended portion 87 along the connector height direction and supports the second extended portion 87 from the rear side in the coupling direction X. That is, substantially the entire second extended portion 87 is the supported portion 84 supported by the second terminal support portion 92.

[0050] The first terminal support portion 91 is formed closer to the transmission case 41 (front side in the coupling direction X) than the second terminal support portion 92. The first terminal support portion 91 is located on the rear side in the coupling direction X of the second extended portion 77 of the connector terminal 71 and contacts a lower end (near the bent portion 78) of the second extended portion 77. The first terminal support portion 91 supports the lower end (the supported portion 74) of the second extended portion 77 from the rear side in the coupling direction X. The supported portion 74 supported by the first terminal support portion 91 is located on the rear side in the coupling direction X of the forked connecting portion 75. That is, the first terminal support portion 91 is configured to support the rear side in the coupling direction X of the forked connecting portion 75.

[0051] The armature 12 (the rotating shaft 13) of the motor 1 is driven and rotated when supplied with power from the external connector inserted into the insertion hole 53a of the external connection unit 53 via the connector terminal 55, the control circuit substrate 61, the connector terminals 71, 81 and the power terminal 34 of the brush holder 21.

[0052] The operation of the present embodiment will be described below.

[0053] When the connector module 4 is coupled to the connector mounting portion 43a of the gear case 41 along the planar motor direction (coupling direction X), the press-fit projection 51d on the side of the connector module 4, which is in Fig. 5, is first pressed into the press-fit hole (not shown) formed on the inside of the connector mounting portion 43a. This positions the connector module 4 with respect to the connector mounting portion 43a.

[0054] Then, the connector module 4 is further pushed in the coupling direction X, so that the insertion portion 34a of the power terminal 34 is inserted into the bifurcated connecting portion 75, 85 of each connector terminal 71, 81. The bifurcated connecting portions 75, 85 are thus electrically connected while sandwiching the insertion portion 34a in the motor power direction by their elastic force.

[0055] In the present embodiment, in the connector terminals 71, 81, the supported portions 74, 84, which are closer to the bifurcated connecting portions 75, 85 than the substrate connecting portions 73, 83, are supported from the rear side in the coupling direction X by the first and second terminal support portions 91, 92. Therefore, the contact load generated when the insertion portion 34a is inserted into the bifurcated connecting portions 75, 85 is absorbed by the first and second terminal support portions 91, 92. This suppresses the load exerted on the connecting part (substrate connecting portions 73, 83) of the connector terminals 71, 81 and the control circuit substrate 61. As a result, the load exerted on the substrate connecting portion 73 is further suppressed.

[0056] Furthermore, since the first terminal support portion 91 supports the back side in the coupling direction X of the bifurcated connection portion 75 in a connector terminal 71, the contact load during the connection of the bifurcated connection portion 75 and the power terminal 34 is absorbed by the first terminal support portion 91. As a result, the contact load exerted on the substrate connection portion 73 is further suppressed.

[0057] Furthermore, in the connector terminals 71, 81 of the present embodiment, the supported portions 74, 84 between the press-fit portions 72, 82 fixed to the connector housing 51 and the bifurcated connecting portions 75, 85 are supported by the first and second terminal support portions 91, 92. That is, deformation of the connector terminals 71, 81 due to the contact load during terminal connection is suppressed because they are supported by the first and second terminal support portions 91, 92 at locations closer to the bifurcated connecting portions 75, 85. As a result, the gap between the connector terminals 71, 81 is easily maintained. Therefore, short circuits caused by contact between the connector terminals 71, 81 and contact of the connector terminals 71, 81 with the control circuit substrate 61 are suppressed.

[0058] The connector terminal 71, 81 of the present embodiment includes a bent portion between the press-fitting portions 72, 82 and the bifurcated connecting portion 75, and therefore has a shape that is particularly easily deformed by the contact load during terminal connection. Therefore, the deformation suppression effect of the first and second terminal support portions 91, 92 is further improved. In the connector terminal 71, the bent portion 78 closest to the bifurcated connecting portion 75 is supported by the first terminal support portion 91. Therefore, the deformation of the first terminal support portion 91 is more effectively suppressed.

[0059] In the coupling manner described above, press-fitting the press-fitting protrusion 51d into the press-fitting hole positions the connector module 4 with respect to the connector mounting portion 43a. Then, the bifurcated connecting portions 75, 85 and the power terminal 34 are electrically in contact with each other and electrically connected. This suppresses connection errors of the bifurcated connecting portions 75, 85 and the power terminal 34 that may occur during the sliding of the connector module 4 and the gear case 41. Furthermore, when the connector module 4 is further slid in the coupling direction X after the bifurcated connecting portions 75, 85 and the power terminal 34 are connected, each hooking piece 51a of the connector housing 51 is elastically hooked onto each hooking portion 43b of the gear case 41, so that the connector housing 51 is fixed to the gear case 41.

[0060] The present embodiment has the advantages described below.(1) When coupling the connector housing 51, one insertion portion 34a of the power terminal 34 is inserted between the bifurcated connection portion 75 of the connector terminal 71, and the other insertion portion 34a is inserted between the bifurcated connection portion 85 of the connector terminal 81. The bifurcated connection portions 75, 85 are each connected to elastically engage the insertion portion 34a in a sandwich manner. Each connector terminal 71, 81 includes the press-fit portion 72, 82 fixed to the connector housing 51, the substrate connection portion 73, 83 connected to the control circuit substrate 61, and the supported portion 74, 84 located closer to the bifurcated connection portion 75, 85 than the substrate connection portion 73, 83.The connector housing 51 includes the first and second terminal support portions 91, 92 for respectively supporting the supported portions 74, 84 from the rear side in the coupling direction X. Therefore, the contact load generated when the power terminal 34 of the motor unit 2 is inserted into the bifurcated connection portions 75, 85 is absorbed by the first and second terminal support portions 91, 92 to suppress the load exerted on the connection part of the connection terminal 71, 81 and the control circuit substrate 61. This suppresses connection errors of the connector terminal 71, 81 and the control circuit substrate 61 caused by the contact load during connection. (2) The supported portion 74 of the connector terminal 71 is arranged on the back side in the coupling direction X of the bifurcated connecting portion 75. Since the supported portion 74 is supported on the back side in the coupling direction X of the bifurcated connecting portion 75 by the first terminal support portion 91, the contact load at the time of terminal connection is preferably absorbed by the first terminal support portion 91. As a result, the load exerted on the substrate connecting portion 73 is further suppressed. (3) The press-fit portions 72, 82 of the connector terminals 71, 81 are located closer to the bifurcated connecting portions 75, 85 than the substrate connecting portions 73, 83. Therefore, the contact load during terminal connection is absorbed not only by the first and second terminal support portions 91, 92, but also by the press-fit portions 72, 82. Therefore, the load exerted on the connecting part of the connector terminals 71, 81 and the control circuit substrate 61 is further suppressed. (4) One of the connector terminals 71 is clamp-shaped by the two bent portions 79, 78 located between the press-fitting portion 72 and the bifurcated connecting portion 75. The other connector terminal 81 is clamp-shaped by the two bent portions 89, 88 located between the press-fitting portion 82 and the bifurcated connecting portion 85. This structure improves the degree of freedom for arranging the bifurcated connecting portions 75, 85 according to the position of the power terminal 34 (insertion portion 34a). (5) At least a part of the second extended portion 77 between the bent portions 79, 78 is formed as the supported portion 74 in the connector terminal 71, and at least a part of the second extended portion 87 between the bent portions 89, 88 is formed as the supported portion 84 in the connector terminal 81. Therefore, the supported portions 74, 84 in the connector terminals 71, 81 are easily configurable. (6) The sockets for the connector terminals 71, 81 are the bifurcated connecting portions 75, 85, which have a bifurcated shape. The bifurcated connecting portions 75, 85 are sandwiched for elastic engagement with the power terminal 34 (insertion portion 34a). With such a structure, the power terminal 34 is inserted between the bifurcated connecting portions 75, 85 and connected thereto when the connector housing 51 is coupled. Therefore, the connection structure is simplified.

[0061] The above embodiment may be modified as described below.

[0062] In the above-described embodiment, the press-in projection 51d for positioning the connector module 4 has a circular cross section; however, it may also have a plus sign-shaped cross section, as shown in Fig. 7. The contact area of the press-in projection 51d with respect to the press-in hole becomes smaller by forming the press-in portion 51d, which is press-fitted into the circular press-in hole on the connector attachment portion 43a side, with a plus sign-shaped cross section. As a result, the insertion load required to insert the press-in projection 51d into the press-in hole can be reduced. In the example shown in Fig.7, a base portion 51e of the press-fit projection 51d is shown having a circular cross section to ensure the shear strength of the press-fit projection 51d.

[0063] In the connector terminal 81 of the above-described embodiment, the supported portion 84 is arranged at a position deflected in the motor-planar direction relative to the bifurcated connecting portion 85. However, the supported portion 84 may be located on the rear side (just behind) of the bifurcated connecting portion 85 in the coupling direction, like the other connecting terminal 71.

[0064] In the above-described embodiment, the press-fitting portions 72, 82 of the connector terminals 71, 81 are arranged closer to the bifurcated connecting portions 75, 85 with respect to the substrate connecting portions 73, 83, but may be arranged on the opposite side (closer to the base ends of the connector terminals 71, 81) of the bifurcated connecting portions 75, 85 with respect to the substrate connecting portions 73, 83.

[0065] In the embodiment described above, the direction (press-in direction of the press-in portions 72, 82 to the press-in recess 57) for fastening the connector terminals 71, 81 to the connector housing 51 is perpendicular to the coupling direction X of the connector housing 51. However, the fastening direction of the connector terminals 71, 81 may, for example, be parallel to the coupling direction X.

[0066] The connector terminals 71, 81 of the above-described embodiment include the bent portion from the press-fitting portions 72, 82 fixed to the connector housing 51 to the bifurcated connecting portions 75, 85; however, they may be formed straight along the planar motor direction from the press-fitting portions 72, 82 to the bifurcated connecting portions 75, 85. This achieves the same advantages as the above embodiment in which the first and second terminal support portions 91, 92 support the supported portions from the rear side in the coupling direction X from the press-fitting portions 72, 82 to the bifurcated connecting portions 75, 85 of the connector terminals 71, 81.

[0067] In the above-described embodiment, the bifurcated connecting portion 75, 85 of each connector terminal 71, 81 is sandwiched for elastically engaging the insertion portion 34a of the power terminal 34 in the motor power direction, but may, for example, sandwich the socket in the axial direction.

[0068] In the connector terminals 71, 81, the structure of the socket into which the power terminal 34 of the motor unit 2 is inserted is not limited to the forked connecting portions 75, 85 of the above-described embodiment, and may be changed to shapes other than the forked shape as long as the power terminal 34 can be inserted and connected when coupling the connector housing 51.

[0069] In the embodiment described above, the connector module 4 is coupled to the gear housing 41 in the direction perpendicular to the axis (planar motor direction); however, it may be coupled, for example, in the axial motor direction.

[0070] In the above-described embodiment, the present invention is applied to the motor 1 used as a drive source of the power window device; however, it may be applied to a motor used to drive a device other than the power window device, such as a vehicle wiper device.

Claims

[1] Engine (1), comprising: a motor unit (2) containing a rotating shaft (13) and a power connection (34); a gear housing (41) coupled to the motor unit (2), the gear housing (41) housing a deceleration mechanism (42) that decelerates and outputs rotation of the rotary shaft (13); a connector module (4) including a connector terminal (55, 71, 81) connected to the power terminal (34), a circuit substrate connected to the connector terminal (55, 71, 81), and a connector housing (51) coupled to the gear housing (41), wherein the connector terminal (55, 71, 81) and the circuit substrate are fixed to the connector housing (51), wherein the power connection (34) is inserted into a socket of the connector connection (55, 71, 81) and connected thereto when coupling the connector housing (51) to the gear housing (41) in a coupling direction (X), the connector terminal (55, 71, 81) includes a rigid portion fixed to the connector housing (51), a substrate connecting portion (73, 83) connected to the circular substrate, and a supported portion (74, 84) located closer to the socket in the coupling direction (X) than the substrate connecting portion (73, 83), wherein the rigid portion is arranged closer to the socket in the coupling direction (X) than the substrate connecting portion (73, 83), and the supported portion (74, 84) is arranged closer to the socket in the coupling direction (X) than the rigid portion, and the connector housing (51) includes a terminal support portion (91, 92) supporting the supported portion (74, 84) from a rear side in the coupling direction (X) such that the supported portion (74, 84) is disposed between the terminal support portion (91, 92) and the socket. [2] The motor (1) according to claim 1, wherein the supported portion (74, 84) of the connector terminal (55, 71, 81) is arranged on the back side of the socket in the coupling direction (X). [3] The motor (1) according to claim 1 or 2, wherein the connector terminal (55, 71, 81) is clamp-shaped and includes a plurality of bent portions (78, 79, 88, 89) between the rigid portion and the socket. [4] The motor of claim 3, wherein the supported portion (74, 84) is at least a part of an extended portion (76, 77, 86, 87) extending between adjacent ones of the bent portions (78, 79, 88, 89) in the connector terminal (55, 71, 81). [5] The motor (1) according to any one of claims 1 to 4, wherein the socket of the connector terminal (55, 71, 81) includes a bifurcated connecting portion (75, 85) having a bifurcated shape, and wherein the bifurcated connecting portion (75, 85) elastically engages the power terminal (34) in a sandwich construction.

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