Circuit-integrated motor

Abstract

To provide a circuit-integrated motor that allows a control substrate to be assembled in a substrate compartment with a small number of parts and assembly man-hours.SOLUTION: A circuit-integrated motor 100 comprises: a motor 10; a control substrate 40 for controlling the motor; a casing 50 covering at least of the control substrate; and a resin substrate holder 110 for fixing control substrate. The casing includes a metal bulkhead section 60 that divides the space between the substrate compartment 51 for housing the control substrate and the motor placement space. The substrate holder is integrally molded with the bulkhead section by insert molding using the bulkhead section as insert parts. The substrate holder includes a base 120 and a coupling 130 that is provided at a location corresponding to a through hole 48 formed in the control substrate and couples the control substrate 40 to the base 120. The coupling portion of the substrate holder contacts at least one of the outer edge region of the through-hole opening or the inner wall of the through-hole on the surface of the control substrate opposite the base to restrain the control substrate.SELECTED DRAWING: Figure 1

Description

[Technical field]

[0001] The present disclosure relates to a circuit-integrated motor in which a motor and a control unit (control board) are integrated into a single module. [Background technology]

[0002] Conventionally, there has been known a circuit-integrated motor in which a motor and a control unit are integrated into a single module. In a circuit-integrated motor, the control board is generally housed in a board housing chamber that is isolated from the motor arrangement space.

[0003] For example, Patent Document 1 describes a drive device (circuit-integrated motor) in which a motor and a controller including a control board and a power board are integrated together. In the drive device described in Patent Document 1, a control board is fastened to a heat sink fastened to a motor case by screws from the motor side, and a power board is attached from the opposite side to the motor. The control board and the power board are covered by a resin cylindrical member that surrounds the heat sink and a cover that is fastened to the cylindrical member. [Prior art documents] [Patent documents]

[0004] [Patent Document 1] JP 2012-143036 A Summary of the Invention [Problem to be solved by the invention]

[0005] In the circuit-integrated motor described in Patent Document 1, the control board is fastened to the heat sink with screws, which not only requires a large number of parts but also requires the drilling of screw holes to form female screws in the heat sink.

[0006] In view of the above circumstances, an object of at least some embodiments of the present invention is to provide a circuit-integrated motor in which a control board can be assembled into a board accommodating chamber with a reduced number of parts and assembly steps. [Means for solving the problem]

[0007] A circuit-integrated motor according to at least some embodiments of the present invention comprises: A motor; A control board for controlling the motor; a casing that covers at least the control board; a resin board holder for fixing the control board; Equipped with The casing includes a metal partition wall that separates a board accommodating chamber for accommodating a control board from a space for arranging the motor, The substrate holder is integrally molded with the partition wall by insert molding using the partition wall as an insert part, The substrate holder is a base located between the control board and the partition wall; a coupling portion that is provided so as to protrude from the base at a position corresponding to a through hole formed in the control board and that couples the control board to the base; Including, The joining portion of the board holder is configured to abut against at least one of the outer peripheral edge region of the opening of the through hole on the surface of the control board opposite the base or the inner wall surface of the through hole, thereby restraining the control board. Effect of the Invention

[0008] According to at least some embodiments of the present invention, the control board and the board holder can be joined by a joint provided on the resin board holder which is integrally molded with the metal partition. Therefore, compared to the case where the control board is fastened to the metal part of the casing (partition part) using screws, the number of parts can be reduced, and the process of drilling screw holes for fixing the control board in the metal part of the casing (partition part) can be omitted. [Brief description of the drawings]

[0009] [Figure 1] 1 is a cross-sectional view showing a schematic diagram of a circuit-integrated motor according to an embodiment; [Diagram 2] FIG. 2 is a perspective view showing the appearance of a board holder of a circuit-integrated motor according to an embodiment; [Diagram 3] 3 is a cross-sectional view of the substrate holder of the embodiment shown in FIG. 2 taken along line AA. [Figure 4A] 3 is a diagram for explaining a process for forming a joint of the substrate holder in the embodiment shown in FIG. 2, showing a state before the formation of a joint 130. FIG. [Figure 4B] 3 is a diagram for explaining the process of forming the joint of the substrate holder of the embodiment shown in FIG. 2, showing a state in the middle of forming the joint. FIG. [Diagram 5] FIG. 13 is a perspective view showing the appearance of a board holder of a circuit-integrated motor according to another embodiment. [Figure 6] 6 is a cross-sectional view taken along line BB of the substrate holder of the embodiment shown in FIG. 5. [Figure 7] 6 is a front view of the board holder of the embodiment shown in FIG. 5, showing the state before the coupling portion is press-fitted into the through hole of the control board. [Figure 8] 1 is a perspective view showing an overall configuration of a circuit-integrated motor according to an embodiment; [Figure 9] FIG. 2 is a perspective view showing a state before a cover is attached to the circuit-integrated motor according to the embodiment; [Figure 10] 1 is a perspective view showing a partition wall portion of an insert-molded product of a circuit-integrated motor according to one embodiment, separated from other portions; [Figure 11] 1 is a perspective view showing only an insert part of an insert-molded product of a circuit-integrated motor according to one embodiment, with a resin portion omitted; DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0010] Hereinafter, some embodiments of the present invention will be described with reference to the accompanying drawings. However, the dimensions, materials, shapes, relative arrangements, etc. of components described as the embodiments or shown in the drawings are merely illustrative examples and are not intended to limit the scope of the present invention.

[0011] Hereinafter, a circuit-integrated motor according to some embodiments will be described with reference to the drawings. The circuit-integrated motor described below is a motor and a control unit (control board) integrated into one module, and may be, for example, a motor device for driving a radiator fan, a motor for driving a vacuum pump, or other in-vehicle motor device. In this specification, unless otherwise specified, the terms "axial direction," "radial direction," and "circumferential direction" refer to the axial direction, radial direction, and circumferential direction, respectively, of the circuit-integrated motor.

[0012] FIG. 1 is a cross-sectional view that illustrates a circuit-integrated motor 100 according to an embodiment. In some embodiments, as shown in the figure, a circuit-integrated motor 100 includes a motor 10, a control board 40 for controlling the motor 10, a casing 50 that covers at least the control board 40, and a board holder 110 for fixing the control board 40. The control board 40 is accommodated in a board accommodation chamber 51 formed by the casing 50.

[0013] The motor 10 includes a stator 20 including a stator core 22, and a rotor 30 having a magnet 32 ​​arranged to face the stator core 22 in the radial direction. A stator coil 24 is wound around the stator core 22. The stator coil 24 is electrically connected to a control board 40. When a current flows through the stator coil 24 via the control board 40, the rotor 30 rotates in the circumferential direction due to the interaction between the magnetic field generated by the stator coil 24 and the magnet 32. The power supplied to the stator coil 24 is controlled by an inverter circuit included in the control board 40.

[0014] In the embodiment shown in FIG. 1, the circuit-integrated motor 100 (100A, 100B) is an outer rotor type motor in which the magnet 32 ​​of the rotor 30 is located on the outer periphery of the stator core 22 of the stator 20. Specifically, as shown in FIG. 1, the stator 20 includes a stator core 22 around which the stator coil 24 is wound, a support shaft 26 that rotatably supports the rotor 30 via a bearing 34, and a base 28 attached to a casing 50. The base 28 is attached to a lower portion of the casing 50 (a partition wall portion 60 described later) using a fastening member (e.g., a bolt) not shown. The stator core 22 and the support shaft 26 each extend in the axial direction from the base 28 toward the opposite side to the casing 50. The stator core 22 is located radially outside the support shaft 26 so as to surround the support shaft 26. The magnet 32 ​​of the rotor 30 is disposed on the outer circumferential side of the stator core 22. The rotor 30 has a double cylindrical structure including an outer circumferential wall 36 and an inner circumferential wall 37, and the outer circumferential wall 36 and the inner circumferential wall 37 are connected to each other via a bottom wall 38. The magnet 32 ​​is attached to the inner circumferential surface of the outer circumferential wall 36. A vent hole 39 is formed between the rotor 30 and the casing 50 (a partition wall portion 60 described later). The vent hole 39 is formed by an axial gap between an outer peripheral wall 36 of the rotor 30 and the casing 50 (a partition wall portion 60 described later).

[0015] In another embodiment, the circuit-integrated motor 100 is an inner rotor type motor in which the rotor 30 is located on the inner circumference side of the stator 20. The inner rotor type circuit-integrated motor 100 has a basic configuration common to the example shown in FIG. 1, except for the positional relationship between the rotor 30 and the stator 20.

[0016] The control board 40 includes a printed wiring board 41 and a plurality of electronic devices 42 mounted on the printed wiring board 41 . The electronic device 42 may be a component of an inverter circuit for controlling the power supplied to the stator coil 24 of the motor 10, and may be, for example, a semiconductor element such as a FET. Alternatively, the electronic device 42 may be a passive element such as a capacitor or a coil.

[0017] 1, the control board 40 includes a heat dissipation member 44 for thermally connecting the electronic device 42 to the partition wall 60 as a heat sink. The heat dissipation member 44 may be a heat via, a thermally conductive grease, a thermally conductive tape, or the like. 1, the heat dissipation member 44 is provided inside the control board 40 so as to form a heat conduction path from the electronic device 42 mounted on the surface of the control board 40 opposite the partition wall portion 60 to the partition wall portion 60 serving as a heat sink. In this case, the heat dissipation member 44 may include a plurality of heat vias 43 penetrating the control board 40. In another embodiment, it is provided between the electronic device 42 and the partition portion 60 so as to form a thermal conduction path from the electronic device 42 mounted on the surface of the control board 40 facing the partition portion 60 to the partition portion 60 as a heat sink.

[0018] The control board 40 may also include a ground terminal 46 that is electrically connected to the bulkhead portion 60 . In the embodiment shown in Figure 1, a screw 47 inserted into a through hole in the control board 40 is screwed into a female thread provided in the partition portion 60 (the second convex portion 61B described later), thereby electrically connecting a ground terminal 46 provided on the surface of the control board 40 facing the partition portion 60 to the partition portion 60.

[0019] The control board 40 configured as described above is accommodated in a board accommodation chamber 51 formed by a casing 50. The casing 50 includes a metal partition wall 60 that separates the board accommodation chamber 51 for accommodating the control board 40 from the arrangement space of the motor 10. The partition wall 60 is provided integrally with a resin board holder 110 for fixing the control board 40. The resin material constituting the board holder 110 may be a thermoplastic resin. In some embodiments, the partition 60 and the substrate holder 110 are configured as an insert molded product 200 in which the metal partition 60 is partially covered by the substrate holder 110. The insert molded product 200 including the partition 60 and the substrate holder 110 is produced by insert molding using the partition 60 as an insert part. Note that insert molding is a molding process in which an insert part is placed in a mold before molding, resin is injected around the insert part, and the insert part and the resin are integrated. In order to ensure the bonding strength between the partition portion 60 and the resin in the insert molding 200, the bonding surface of the partition portion 60 with the resin (substrate holder 110) may be roughened by laser irradiation, roughening using chemicals, anodizing, etc.

[0020] The partition portion 60 includes a board-facing surface 62 that faces the control board 40 in the axial direction, and an outer circumferential edge 64 that is provided by protruding on the side opposite the motor arrangement space (the board accommodating chamber 51 side) so as to surround the board-facing surface 62. The board-facing surface 62 of the partition portion 60 forms the bottom surface of the board accommodating chamber 51.

[0021] The substrate-facing surface 62 of the partition wall 60 may be provided with one or more types of protrusions 61 for achieving desired functions. 1, the heat dissipation member 44 includes a first protrusion 61A having a female thread into which the screw 47 is screwed, and a second protrusion 61B in contact with the heat dissipation member 44. The first protrusion 61A is provided on the board-facing surface 62 to establish an electrical connection between the ground terminal 46 of the control board 40 and the partition wall 60. The second protrusion 61B is provided on the board-facing surface 62 to establish a thermal connection between the electronic device 42 and the partition wall 60. Note that the board-facing surface 62 of the partition portion 60, except for the convex portion 61, may be flat or may have a concave portion. For example, when the electronic device 42 is mounted on the surface of the control board 40 facing the board-facing surface 62, the board-facing surface 62 may have a concave portion to avoid interference with the electronic device 42. The material constituting the partition wall 60 is not particularly limited, but for example, an aluminum alloy having excellent thermal and electrical conductivity can be used.

[0022] The outer peripheral edge 64 of the partition portion 60 may be provided continuously around the entire circumference, or may have a notch formed in a portion of the circumferential range. In the exemplary embodiment shown in FIG. 1, the outer peripheral edge 64 of the partition portion 60 has a partial notch at a circumferential position where the terminal 70 is disposed, and is circumferentially discontinuous at the location of the notch.

[0023] 1, in some embodiments, the partition portion 60 has an attachment portion 66 that protrudes radially outward. The attachment portion 66 is used to install the circuit-integrated motor 100. For example, when the circuit-integrated motor 100 is an in-vehicle motor, the circuit-integrated motor 100 may be attached to the vehicle body via the attachment portion 66.

[0024] As described above, the insert molded product 200 in which the partition wall 60 is an insert part includes the resin board holder 110 that is integral with the partition wall 60 and partially covers the surface of the partition wall 60. The board holder 110 is a part of the resin part of the insert molded product 200 that is located inside the board accommodating chamber 51 and has the function of fixing the control board 40 to the casing 50. As shown in FIG. 1, the board holder 110 includes a base 120 located between the control board 40 and the partition wall portion 60 , and a coupling portion 130 that mechanically couples the control board 40 to the base 120 .

[0025] Here, the structure of the substrate holder 110 (110A, 110B) according to some embodiments will be described with reference to FIG. 1 and FIG. 2 to FIG. Fig. 2 is a perspective view showing the appearance of substrate holder 110A of circuit-integrated motor 100 according to one embodiment. Fig. 3 is a cross-sectional view taken along line AA of substrate holder 110A according to the embodiment shown in Fig. 2. Figs. 4A and 4B are diagrams for explaining the process of forming joint 130A of substrate holder 110A according to the embodiment shown in Fig. 2, with Fig. 4A showing the state before joint 130 is formed and Fig. 4B showing the state during the formation of joint 130A. Fig. 5 is a perspective view showing the appearance of a board holder 110B of a circuit-integrated motor 100 according to another embodiment. Fig. 6 is a cross-sectional view taken along line BB of the board holder 110B according to the embodiment shown in Fig. 5. Fig. 7 is a front view of the board holder 110B according to the embodiment shown in Fig. 5, showing the state before the coupling portion 130B is press-fitted into the through-hole 48 of the control board 40. For ease of explanation, in Figs. 2 and 5, the control board 40 and the partition wall 60 are omitted, and only the board holder 110 (110A, 110B) is shown.

[0026] 1 to 3 and 5 to 7, the base 120 of the substrate holder 110 (110A, 110B) has a joining surface 122 joined to the substrate facing surface 62 of the partition portion 60, and a substrate supporting surface 124 for supporting the control substrate 40. The substrate supporting surface 124 is the surface of the base 120 opposite to the joining surface 122. The substrate supporting surface 124 of the base 120 may be a flat surface along the surface of the control substrate 40.

[0027] The coupling portion 130 (130A, 130B) of the substrate holder 110 (110A, 110B) is provided to protrude from the base 120 toward the control substrate 40. The coupling portion 130 is a protrusion provided on the substrate support surface 124 of the base 120. 1, 3, and 6, the coupling portion 130 is provided to protrude from the base 120 at a position corresponding to the through hole 48 formed in the control board 40. The coupling portion 130 protrudes in the axial direction from the through hole 48 of the control board 40 to the opposite side of the base 120 with the control board 40 in between. In other words, the coupling portion 130 is at least partially located outside the through hole 48 with respect to the surface 45 of the control board 40 opposite the surface that abuts against the board support surface 124 of the base 120.

[0028] In some embodiments, as shown in Figures 3 and 6, the connecting portion 130 (130A, 130B) restrains the control board 40 by abutting against the outer peripheral edge region of the opening of the through hole 48 on the surface 45 of the control board 40 opposite the base 120, or against the inner wall surface of the through hole 48. That is, the connecting portion 130 (130A, 130B) has a restraining surface 132 (132A, 132B) that abuts against the outer peripheral edge region of the opening of the through hole 48 on the surface 45 of the control board 40 or the inner wall surface of the through hole 48 to restrain the control board 40.

[0029] 2 and 3, the coupling portion 130A has a crimped portion 131 that protrudes from the through hole 48 of the control board 40 to the opposite side of the base 120 with the control board 40 in between. The crimped portion 131 has a larger diameter than the through hole 48 of the control board 40. In other words, the maximum diameter d1 of the crimped portion 131 is larger than the inner diameter d0 of the through hole 48. The crimping portion 131 has a restraining surface 132A that abuts against an outer peripheral edge region of the opening of the through hole 48 on the surface 45 of the control board 40. The restraining surface 132A of the crimping portion 131 may be an annular region on the outer surface of the crimping portion 131 that is defined between an inner circumferential circle having a diameter d0 and an outer circumferential circle having a diameter d1 (>d0). The coupling portion 130A is located inside the through hole 48 and has a columnar portion 133 that connects the crimped portion 131 and the base 120. The outer diameter of the columnar portion 133 is smaller than the inner diameter d0 of the through hole 48 and the maximum outer diameter d1 of the crimped portion 131. Therefore, in the coupling portion 130A, a step is formed between the columnar portion 133 and the crimped portion 131, the step being defined by a step surface including the restraining surface 132A. The step surface of the coupling portion 130A including the restraining surface 132A extends from the columnar portion 133 toward the outside in the radial direction of the columnar portion 133.

[0030] As shown in FIGS. 4A and 4B, coupling portion 130A having crimping portion 131 is formed by crimping the tip of columnar portion 133 protruding from base 120 using crimping device 300. The resin portion of the insert molded product 200 that becomes the board holder 110 has the base 120 and a columnar portion 133 protruding from the base 120 before crimping. The control board 40 is placed on the base 120 so that the columnar portion 133 is inserted into the through hole 48. In this state, the tip of the columnar portion 133 protrudes from the through hole 48 and extends to the opposite side of the base 120 across the control board 40 (FIG. 4A). When the tip of the columnar portion 133 is crimped by the crimping device 300, the tip of the columnar portion 133 is deformed, and a crimped portion 131 having a diameter larger than the through hole 48 is formed. In this way, the restraining surface 132A of the crimping portion 131 abuts against the outer peripheral edge region of the opening of the through hole 48 on the surface 45 of the control board 40, and the control board 40 is held between the restraining surface 132A and the board support surface 124.

[0031] The type of the crimping device 300 is not particularly limited as long as it is capable of performing resin crimping (resin staking). The crimping device 300 may be, for example, a thermal crimping device that presses a punch heated by a heater against the tip of the cylindrical portion 133, an ultrasonic crimping device that applies ultrasonic waves from a horn to the tip of the cylindrical portion 133, or an infrared crimping device that presses a punch against the tip of the cylindrical portion 133 while heating it with infrared rays.

[0032] In the embodiment shown in FIGS. 5 to 7, the coupling portion 130B is press-fitted into the through-hole 48 of the control board 40 to couple the control board 40 to the board holder 110B (base 120). The coupling portion 130B has a plurality of ribs (crush ribs) 134 on its outer circumferential surface, which extend from the base 120 along the protruding direction of the coupling portion 130B. The ribs 134 are provided so as to protrude from the cylindrical portion 135 of the coupling portion 130B to the radially outer side of the cylindrical portion 135. The maximum outer diameter d4 of the coupling portion 130B including the ribs 134 before the coupling portion 130B is pressed into the through hole 48 is larger than the diameter d3 of the cylindrical portion 135 (see FIG. 7). The inner diameter of the through hole 48 is larger than the diameter d3 of the cylindrical portion 135 and smaller than the maximum outer diameter d4 of the coupling portion 130B. Therefore, when the coupling portion 130B is pressed into the through hole 48, the ribs 134 are crushed and deformed, and the deformed ribs 134 come into contact with the inner wall surface of the through hole 48, thereby restraining the control board 40. In this case, the surface of the deformed rib 134 functions as a restraining surface 132B of the coupling portion 130B. 5 and 7, the height of each rib 134 based on the outer circumferential surface of coupling portion 130B decreases with increasing distance from base 120. That is, the protruding height h of each rib 134 from the outer circumferential surface of cylindrical portion 135 of coupling portion 130B decreases with increasing distance from base 120. For this reason, the outer diameter of coupling portion 130B including rib 134 gradually decreases toward the tip side of coupling portion 130B.

[0033] In another embodiment (not shown), the crimped portion is formed by crimping and deforming the tip portion of the coupling portion 130B shown in Figures 5 to 7. In this case, the coupling portion 130B abuts against both the outer peripheral edge region of the opening of the through hole 48 on the surface 45 of the control board 40 and the inner wall surface of the through hole 48, and has both the constraint surface 132A shown in Figure 3 and the constraint surface 132B shown in Figure 6.

[0034] The insert molding 200 may include other resin parts in addition to the substrate holder 110 (110A, 110B) configured as described above. In some embodiments, as shown in FIG. 1, the insert molded product 200 includes, as other resin parts, at least one of a first resin part 150 that partially forms the peripheral wall of the board accommodating chamber 51, or a terminal holder (connector housing) 80 for holding a terminal 70 for connecting the control board 40 to an external device. 1, the insert molded product 200 includes both the first resin part 150 and the terminal holder 80 as resin parts other than the substrate holder 110. In this case, the insert molded product 200 is produced by insert molding using the partition part 60 and the terminal 70 as insert parts, and has a configuration in which the metallic partition part 60 and the terminal 70 are partially embedded in the resin parts (substrate holder 110, first resin part 150, and terminal holder 80). The terminal holder 80 may be a resin part of the insert molded product 200 that is provided continuously with the first resin part 150 without any seams.

[0035] As shown in FIG. 1, the first resin portion 150 of the insert molding 200 constitutes the casing 50 together with the partition portion 60 and the cover portion 90 . The first resin part 150 is provided along the entire outer periphery 64 of the partition part 60 so as to surround the substrate accommodating chamber 51. In the example shown in Fig. 1, the first resin part 150 is provided continuous with the substrate holder 110 provided on the substrate-facing surface 62 of the partition part 60 in the substrate accommodating chamber 51. Specifically, the base 120 of the substrate holder 110 located in the left end region in the substrate accommodating chamber 51 in Fig. 1 is continuous with the first resin part 150. The first resin part 150 of the insert molded product 200 is welded to the second resin part 160 of the cover part 90, and forms the peripheral wall of the substrate accommodating chamber 51 together with the second resin part 160. That is, after the control board 40 is assembled to the substrate holder 110 of the insert molded product 200, the second resin part 160 of the cover part 90 is welded to the first resin part 150 of the insert molded product 200, so that the boundary of the substrate accommodating chamber 51 is defined by the insert molded product 200 and the cover part 90. The substrate accommodating chamber 51 has a radial boundary formed by the first resin part 150 and the second resin part 160, and an axial boundary formed by the substrate facing surface 62 of the partition part 60 and the inner surface of the cover part 90. The first resin part 150 and the second resin part 160 may be joined by, for example, spin welding, laser welding, or ultrasonic welding. When the spin welding method is employed, it is desirable that the peripheral wall of the substrate accommodating chamber 51 formed by the first resin part 150 and the second resin part 160 has a circular shape. In the exemplary embodiment shown in Fig. 1, the cover part 90 is a resin cover entirely made of a resin material. In other embodiments, the cover part 90 includes a resin part including the second resin part 160 and a part formed of a different material other than a resin material.

[0036] As described above, the insert molded product 200 has a configuration in which the metallic partition portion 60 and the terminals 70 are partially embedded in the resin portions (the substrate holder 110, the first resin portion 150, and the terminal holder 80). In one embodiment, the substrate holder 110 is provided seamlessly and continuously with the terminal holder 80 via the first resin portion 150 provided around the entire circumference of the casing 50. 1, the terminal 70 is a metal part provided penetrating the casing 50, and has a first end 72 located within the board accommodating chamber 51 and connected to the control board 40, and a second end 74 located outside the board accommodating chamber 51. The first end 72 of the terminal 70 is electrically connected to the circuit pattern of the control board 40 via, for example, solder 71. The second end 74 of the terminal 70 is connected to an external device via a cable (not shown). 1, a tip 73 of a first end 72 of terminal 70 is bent in a direction (axial direction) from the board-facing surface 62 of the partition portion 60 toward the control board 40, and is inserted into a through hole 49 provided in the control board 40. The tip 73 of the first end 72 inserted into the through hole 49 is connected to the circuit pattern of the control board 40 by solder 71.

[0037] In the embodiment shown in Figure 1, the terminal holder 80 includes a base portion 82 joined to the substrate-facing surface 62 of the partition portion 60, an intermediate portion 84 located on the outer periphery of the base portion 82, and an extension portion 86 extending outside the substrate accommodating chamber 51. A base portion 82 of the terminal holder 80 is provided on the board-facing surface 62 so as to be at least partially located within the board accommodating chamber 51. A first end portion 72 of the terminal 70 protrudes from the base portion 82 of the terminal holder 80, and a tip portion 73 of the first end portion 72 bent toward the control board 40 is inserted into the through hole 49 of the control board 40. The intermediate portion 84 of the terminal holder 80 is joined to the outer peripheral edge 64 of the partition portion 60. Here, in the example shown in Fig. 1, the outer peripheral edge 64 of the partition portion 60 has a partial notch at a circumferential position where the terminals 70 are arranged, and the joint portion between the intermediate portion 84 of the terminal holder 80 and the outer peripheral edge 64 of the partition portion 60 is not shown. However, even in the embodiment shown in Fig. 1, the intermediate portion 84 of the terminal holder 80 is joined to a portion of the outer peripheral edge 64 excluding the notch (a portion adjacent to the notch in the circumferential direction). The extension portion 86 of the terminal holder 80 extends radially outward from the intermediate portion 84 so as to be located on the opposite side of the base portion 82 with the intermediate portion 84 in between in the radial direction. The extension portion 86 of the terminal holder 80 has an engagement claw 87 with which an end of a cable for connecting to an external device can be engaged, and a recess 88 in which the second end 74 of the terminal 70 is exposed. The second end 74 of the terminal 70 extends radially outward along the extension portion 86 within the recess 88.

[0038] Next, the detailed structure of the circuit-integrated motor 100 according to some embodiments will be described with reference to FIGS. Figures 8 to 11 are oblique views showing a circuit-integrated motor 100 according to one embodiment, where Figure 8 shows the overall configuration of the circuit-integrated motor 100, Figure 9 shows the state of the circuit-integrated motor 100 before the cover is attached, Figure 10 shows the partition portion 60 of the insert molded product 200 separated from other parts, and Figure 11 shows only the insert parts of the insert molded product 200 with the resin parts omitted. In the following, description of the parts of the circuit-integrated motor 100 that are common to the configuration described above with reference to Figs. 1 to 3 will be simplified or omitted.

[0039] 8 to 11, the insert molded product 200 has a configuration in which a metallic partition portion 60 and terminals 70 are partially covered by a resin portion including a board holder 110 (110A), a first resin portion 150, and a terminal holder 80. That is, the partition portion 60, the terminals 70, the board holder 110 (110A), the first resin portion 150, and the terminal holder 80 are integrally provided by insert molding using the partition portion 60 and the terminals 70 as insert parts (see FIG. 11). 10, the resin parts (110, 150, 80) of the insert molded product 200 are continuous without any seams. Specifically, the base 120 of the substrate holder 110 (110A) is connected to the inner peripheral surface of the annular first resin part 150 that forms the peripheral wall of the substrate accommodating chamber 51, and the substrate holder 110 (110A) and the first resin part 150 are continuous without any seams. The middle part 84 of the terminal holder 80 is connected to the first resin part 150, and the terminal holder 80 and the first resin part 150 are continuous without any seams. Although FIG. 10 shows the partition wall portion 60 of the insert molded product 200 separated from the other portions, in reality, the partition wall portion 60 forms the insert molded product 200 integrally with the other portions, and the partition wall portion 60 cannot be separated from the other portions without being destroyed.

[0040] As shown in Fig. 9, the control board 40 is assembled to the board holder 110 (110A) of the insert molding product 200. Specifically, the control board 40 is mechanically coupled to the base 120 of the board holder 110 (110A) by a coupling portion 130 (130A) at a position corresponding to a through hole 48 (see Fig. 1) located at a corner of the control board 40. In the example shown in Fig. 9, the coupling portion 130 is the coupling portion 130A including the crimped portion 131 shown in Figs. 2 and 3. In another embodiment, the coupling portion 130 is the coupling portion 130B having the rib 134 shown in Figs. 5 to 7 on its outer circumferential surface. The ground terminal (ground terminal 46 in FIG. 1) of the control board 40 is electrically connected to the partition wall portion 60 by screwing a screw 47 into the female thread of the first protrusion 61A (see FIG. 10 and FIG. 11) of the partition wall portion 60.

[0041] In the embodiment shown in FIG. 9, the control board 40 is electrically connected to the motor wires 25 which are the ends of the stator coil 24 of the motor 10, and to a first end 72 of the terminal 70 of the insert molding product 200. The motor wire 25 passes through an opening 202 (see Figs. 10 and 11) provided in the partition wall portion 60 of the insert molding 200, enters the board housing chamber 51 from the arrangement space of the motor 10, and the tip of the motor wire 25 is inserted into a through hole provided in the control board 40. In addition, the opening 202 has a gap around the motor wire 25 sealed with a rubber material to ensure the airtightness of the board housing chamber 51. The tip 73 of the first end 72 of the terminal 70 is bent in the axial direction from the board-facing surface 62 of the partition wall portion 60 toward the control board 40, and is inserted into the through hole 49 provided in the control board 40. The tip of the motor wire 25 protruding from the surface of the control board 40 and the tip 73 of the first end 72 of the terminal 70 are electrically connected to the circuit pattern of the control board 40 by, for example, soldering. The electronic device 42 mounted on the control board 40 is thermally connected to the partition wall 60 of the insert molded product 200 via a heat dissipation member (not shown).

[0042] As shown in FIGS. 9 and 10, a resin terminal holder (connector housing) 80 that holds the terminals 70 extends radially from the inside to the outside of the board accommodating chamber 51 as a part of the resin portion of the insert molding 200 . The terminal holder 80 includes a base portion 82 located at the innermost position in the radial direction, an extension portion 86 located at the outermost position in the radial direction, and an intermediate portion 84 located between the base portion 82 and the extension portion 86. The base portion 82 is joined to the substrate-facing surface 62 of the partition portion 60 in the substrate accommodating chamber 51. The terminal holder 80 is provided integrally with a first resin portion 150 that forms the peripheral wall of the substrate accommodating chamber 51 together with the second resin portion 160 of the cover portion 90. The first resin portion 150 is provided continuously around the entire circumference. The upper end surface of the first resin portion 150 that is provided continuously around the entire circumference is a joint surface with the second resin portion 160 of the cover portion 90, and is a flat surface along a plane perpendicular to the axial direction. Also, as shown in FIG. 9 and FIG. 10, the upper end surface of the first resin portion 150 is circumferentially shaped with the rotation axis of the rotor 30 of the motor 10 as the center. Therefore, the first resin portion 150 and the second resin portion 160 can be joined by spin welding.

[0043] In some embodiments, as shown in FIGS. 10 and 11, the partition wall 60 of the insert molded product 200 has irregularities on the surface to be bonded to the resin, from the viewpoint of improving the strength of the insert molded product 200. Specifically, a plurality of vertical ribs 65 are formed on the inner peripheral surface of the outer peripheral edge 64 of the partition wall portion 60, and recesses corresponding to the vertical ribs 65 are formed in the first resin portion 150 of the insert molded product 200. The multiple vertical ribs 65 each extend along the axial direction on the inner peripheral surface of the outer peripheral edge 64. Moreover, the partition portion 60 has a notch 68 provided in the outer peripheral edge 64 so that the terminal 70 can pass through, and a recess 69 provided in the board-facing surface 62 so as to be connected to the notch 68. Therefore, the base portion 82 and the intermediate portion 84 of the terminal holder 80 of the insert molding product 200 have shapes complementary to the notch 68 and the recess 69 of the partition portion 60.

[0044] The characteristic configurations of the circuit-integrated motors according to the above-described several embodiments can be summarized as follows.

[0045] [1] In some embodiments, the circuit-integrated motor (100) includes: A motor (10), a control board (40) for controlling the motor (10); a casing (50) that covers at least the control board (40); a resin board holder (110) for fixing the control board (40); Equipped with The casing (50) includes a metal partition wall (60) that separates a board housing chamber (51) for housing the control board (40) from a space for arranging the motor (10). The substrate holder (110) is molded integrally with the partition wall (60) by insert molding using the partition wall (60) as an insert part. The substrate holder (110) a base (120) located between the control board (40) and the partition wall (60); a coupling portion (130) that protrudes from the base (120) at a position corresponding to the through hole (48) formed in the control board (40) and couples the control board (40) to the base (120); Including, The connecting portion (130) of the substrate holder (110) is configured to abut against at least one of the outer peripheral edge region of the opening of the through hole (48) on the surface of the control substrate (40) opposite the base (120) or the inner wall surface of the through hole (48), thereby restraining the control substrate (40).

[0046] According to the above configuration [1], the control board (40) and the board holder (110) can be connected by the connecting portion (130) provided on the resin board holder (110) which is integrally molded with the metal partition portion (60). Therefore, compared to the case where the control board is fastened to the metal part of the casing (partition part) using screws, the number of parts can be reduced, and the process of drilling screw holes for fixing the control board in the metal part of the casing (partition part) can be omitted.

[0047] [2] In some embodiments, in the configuration of [1] above, The connecting portion (130A) has a crimping portion (131) having a diameter larger than the through hole (48), The crimping portion (131) is located on the opposite side of the control board (40) from the base (120). The control board (40) is held between the base (120) and the crimped portion (131) of the board holder (40).

[0048] According to the configuration [2] above, for the reasons described in [1] above, it is possible to reduce the number of parts and the number of assembly steps. In addition, since the cylindrical portion (133) before crimping serves to position the control board (40), the assembly of the control board (40) becomes easier.

[0049] [3] In some embodiments, in the configuration of [1] or [2] above, The connecting portion (130B) has a plurality of ribs (134) on an outer circumferential surface thereof, the ribs (134) extending in a direction in which the connecting portion (130B) protrudes from the base (120); The control board (40) is held in the board holder (110B) by press-fitting the coupling portion (130B) into the through hole (48).

[0050] According to the configuration [3] above, for the reasons described in [1] above, it is possible to reduce the number of parts and the number of assembly steps. In addition, since the joint portion (130B) serves to position the control board (40), the assembly of the control board (40) becomes easier.

[0051] [4] In some embodiments, in the configuration of [3] above, The height (h) of the rib (134) based on the outer circumferential surface of the connecting portion (130B) decreases with increasing distance from the base (120).

[0052] According to the above configuration [4], the coupling portion (130B) can be easily press-fitted into the through-hole (48) of the control board (40).

[0053] [5] In some embodiments, in any one of the configurations [1] to [4] above, The electronic device (42) of the control board (40) is thermally connected to the partition wall (60) serving as a heat sink via a heat dissipation member (44).

[0054] According to the configuration [5] above, the metal partition portion (60) for separating the substrate accommodating chamber (51) from the motor arrangement space is made to function as a heat sink, thereby making it possible to realize a circuit-integrated motor (100) with excellent reliability using a reduced number of parts.

[0055] [6] In some embodiments, in any one of the configurations [1] to [5] above, The ground terminal (46) of the control board (40) is electrically connected to the partition wall (60).

[0056] According to the configuration [6], the metal partition wall (60) for separating the board housing chamber (51) from the motor arrangement space can be used as a ground to stabilize the reference potential of the control board (40). This makes it possible to realize a highly reliable circuit-integrated motor (100) with a reduced number of parts.

[0057] [7] In some embodiments, in any one of the configurations [1] to [6] above, The partition wall (60) is made of an aluminum alloy.

[0058] According to the above configuration [7], the partition (60) made of a lightweight aluminum alloy can be used, thereby making it possible to reduce the weight of the circuit-integrated motor (100). In addition, since aluminum alloys have excellent thermal conductivity and electrical conductivity, they are suitable as materials for the partition wall portion (60) when the partition wall portion (60) is to function as a heat sink or ground, as in [5] or [6] above.

[0059] [8] In some embodiments, in any one of the configurations [1] to [7] above, The circuit integrated motor (100) is A terminal (70) for connecting the control board (40) to an external device; a resin terminal holder (80) for holding a terminal (70); Equipped with The terminal holder (80) is molded integrally with the partition (60), the terminals (70) and the board holder (110) by insert molding using the partition (60) and the terminals (70) as insert parts.

[0060] According to the above configuration [8], the resin part of the insert molding (200) also functions as the terminal holder (80). Therefore, it is not necessary to fabricate a connector part in which terminals are embedded in a resin terminal holder (connector housing) separately from the insert molding (200), and the number of parts can be reduced.

[0061] [9] In some embodiments, in any one of the configurations [1] to [8] above, The casing (50) is a first resin portion (150) integrally molded with the partition portion (60) and the substrate holder (110) by insert molding using the partition portion (60) as an insert part; a cover portion (90) including a second resin portion (160) welded to the first resin portion (160), and defining a substrate accommodating chamber (51) together with the partition portion (60) and the first resin portion (150); Including, The peripheral wall of the substrate accommodating chamber (51) is formed by a first resin part (150) and a second resin part (160) that are welded to each other.

[0062] According to the configuration [9] above, the partition portion (60) for separating the board accommodating chamber (51) from the motor arrangement space and the first resin portion (110) are integrally provided, and the second resin portion (120) of the cover portion (90) is welded to the first resin portion (110). This makes it possible to realize a board accommodating chamber (51) having a sealed structure with a small number of parts and assembly labor.

[0063]

[10] In some embodiments, in any one of the configurations [1] to [9] above, The motor (10) a stator (20) including a stator core (22), attached to the partition wall (60) so as to be located on the opposite side of the partition wall (60) from the substrate accommodating chamber (51); A stator coil (24) wound around a stator core (22); a cylindrical rotor (30) disposed on an outer circumferential side of the stator core (22); a magnet (32) provided on the inner circumferential side of the rotor (30) so as to face the stator core (22) in the radial direction; Including, An air vent (39) is formed between the rotor (30) and the partition wall (60).

[0064] According to the configuration

[10] above, by adopting an outer rotor type motor in which the magnets (32) of the rotor (30) are positioned on the outer periphery of the stator core (22), unlike an inner rotor type motor, a cylindrical motor housing for holding the stator on the outer periphery of the rotor is not required. Therefore, there is no need to provide an interface between the outer periphery of the partition wall (60) and the cylindrical motor housing, and the shape of the partition wall (60) can be simplified, thereby reducing the manufacturing cost of the mold for the insert molding of the above [1]. In addition, by employing an outer rotor type motor, it is possible to omit a cylindrical motor housing that is necessary in the case of an inner rotor type motor, and to form an air vent (39) between the rotor (30) and the partition wall (60). As a result, the air flowing through the air vent (39) can effectively exhaust heat generated by the control board (40) and the motor (10), which are located on both sides of the partition wall (60).

[0065] Although several embodiments of the present invention have been described above, it is of course possible to add modifications to the above-described embodiments without departing from the spirit of the present invention. In particular, in Fig. 1 and Fig. 8 to Fig. 11, the insert molded product 200 includes the partition wall 60, the terminal 70, the board holder 110, the terminal holder 80, and the first resin part 150. However, in the present invention, the insert molded product 200 is not limited to the illustrated example as long as it includes the partition wall 60 and the board holder 110. For example, a connector part having terminals embedded in a resin terminal holder (connector housing) may be attached to the insert molded product 200 including the partition wall 60 and the board holder 110 or the cover part 90. In addition, when the insert molded product 200 does not include the first resin part 150, the board accommodating chamber 51 may be formed by fastening a metal cover part to the partition wall 60 of the insert molded product 200 with a screw. In addition, in this specification, the expressions "comprise," "include," or "have" a certain element are not exclusive expressions that exclude the presence of other elements. [Explanation of symbols]

[0066] 10: Motor 20: Stator 22: Stator core 24: Stator coil 30: Rotor 32: Magnet 39: Ventilation hole 40: Control board 42: Electronic Devices 44: Heat dissipation material 45: Surface 46: Ground terminal 48:Through hole 50: Casing 51: Substrate storage room 60: Partition wall 64: Outer edge 70: Terminal 80: Terminal holder 90: Cover part 100: Circuit integrated motor 110 (100A, 100B): Circuit board holder 120: Bass 130(130A,130B):Joining part 131: Crimping part 134: Rib 150: First resin part 160: Second resin part 200: Insert molding

Claims

1. A motor; A control board for controlling the motor; a casing that covers at least the control board; a resin substrate holder for fixing the control substrate; Equipped with the casing includes a metal partition wall that separates a board accommodating chamber for accommodating the control board from a space for arranging the motor, the substrate holder is integrally molded with the partition wall by insert molding using the partition wall as an insert part, The substrate holder includes: a base located between the control board and the partition wall; a coupling portion that protrudes from the base at a position corresponding to a through hole formed in the control board and couples the control board to the base; Including, The coupling portion of the board holder is configured to abut against at least one of an outer peripheral edge region of the opening of the through hole on the surface of the control board opposite to the base or an inner wall surface of the through hole, thereby restraining the control board. Motor with integrated circuit.

2. The coupling portion has a crimped portion having a diameter larger than that of the through hole, the crimping portion is located on the opposite side of the control board from the base, The control board is held between the base and the crimped portion of the board holder. The circuit-integrated motor according to claim 1 .

3. The coupling portion has a plurality of ribs on an outer circumferential surface thereof, the ribs extending from the base along a protruding direction of the coupling portion, The control board is held by the board holder by press-fitting the coupling portion into the through hole. The circuit-integrated motor according to claim 1 .

4. The height of the rib based on the outer circumferential surface of the connecting portion decreases with increasing distance from the base. The circuit-integrated motor according to claim 3.

5. The electronic device of the control board is thermally connected to the partition wall portion as a heat sink via a heat dissipation member.

4. The circuit-integrated motor according to claim 1.

6. The ground terminal of the control board is electrically connected to the partition wall.

4. The circuit-integrated motor according to claim 1.

7. The partition is made of an aluminum alloy.

4. The circuit-integrated motor according to claim 1.

8. A terminal for connecting the control board to an external device; a terminal holder made of resin for holding the terminal; Equipped with The terminal holder is integrally molded with the partition wall portion, the terminals, and the board holder by the insert molding using the partition wall portion and the terminals as the insert parts.

4. The circuit-integrated motor according to claim 1.

9. The casing comprises: a first resin portion integrally molded with the partition wall portion and the substrate holder by insert molding using the partition wall portion as the insert part; a cover portion including a second resin portion welded to the first resin portion, the cover portion defining the substrate accommodating chamber together with the partition portion and the first resin portion; Including, The peripheral wall of the substrate accommodating chamber is formed by the first resin part and the second resin part that are welded to each other.

4. The circuit-integrated motor according to claim 1.

10. The motor is a stator including a stator core, the stator being attached to the partition wall so as to be located on the opposite side of the partition wall from the substrate accommodating chamber; A stator coil wound around the stator core; a cylindrical rotor disposed on an outer circumferential side of the stator core; a magnet provided on an inner circumferential side of the rotor so as to face the stator core in a radial direction; Including, A vent is formed between the rotor and the partition.

4. The circuit-integrated motor according to claim 1.

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