Bus bar module for rotary electric machine

Abstract

To provide a bus bar module for a rotary electric machine, which can suppress the positional deviation of bus bars.SOLUTION: A bus bar module 94 includes: bus bars 10, 20, 30, 40 which are arranged with intervals between each other in a first direction X and juxtaposed in a second direction Y; and a holding member 50 which covers the bus bars 10, 20, 30, 40. The bus bars 10, 20, 30 include: first connection parts 11, 21, 31, respectively, extending in the first direction X; second connection parts 12, 22, 32, respectively, extending in a third direction Z; and intermediate parts, respectively, extending in the second direction Y between the first connection parts 11, 21, 31 and the second connection parts 12, 22, 32. The holding member 50 includes: a first holding part 51 which covers the first and second bus bars 10, 20 and intervenes between the first and second bus bars 10, 20; and a second holding unit 56 which covers the first holding part 51 and the third bus bar 30. The third bus bar 30 contacts the first holding part 51.SELECTED DRAWING: Figure 2

Description

[Technical field]

[0001] The present disclosure relates to a busbar module for a rotating electric machine. [Background technology]

[0002] Patent Document 1 discloses a bus bar unit used in a stator for a rotating electric machine. This bus bar unit has a bus bar electrically connected to a coil of the stator, and a resin holding member that holds the bus bar.

[0003] The coil is made up of three phase coils: a first phase coil, a second phase coil, and a third phase coil. The bus bar has a first bus bar connected to the first phase coil, a second bus bar connected to the second phase coil, a third bus bar connected to the third phase coil, and a neutral bus bar connected to the neutral wire of the coil.

[0004] The holding member integrally holds the first bus bar, the second bus bar, the third bus bar, and the neutral bus bar. Such a bus bar unit is molded by inserting each bus bar into a molding die that molds the retaining member, and then filling a cavity formed by the molding die and each bus bar with molten resin. [Prior art documents] [Patent documents]

[0005] [Patent Document 1] JP 2020-167843 A Summary of the Invention [Problem to be solved by the invention]

[0006] In such a busbar unit (hereinafter, busbar module) for a rotating electric machine, the busbars are insulated from each other by interposing a holding member between each busbar. However, if the cross-sectional area of ​​the gap between the busbars is small, it becomes difficult for the molten resin to flow through the gap. As a result, if the cross-sectional area of ​​the flow path on the opposite side of the gap across the busbar in the cavity is larger than the cross-sectional area of ​​the gap, a difference occurs between the flow pressure of the molten resin flowing through the gap and the flow pressure of the molten resin flowing through the flow path. This causes a problem in that the busbar is easily displaced from its correct position due to this pressure difference.

[0007] An object of the present disclosure is to provide a bus bar module for a rotating electric machine that can suppress misalignment of the bus bar. [Means for solving the problem]

[0008] A busbar module for a rotating electric machine according to the present disclosure is a busbar module electrically connected to a coil of a stator constituting a rotating electric machine, and includes a plurality of bus bars arranged at intervals from each other in the first direction and arranged side by side in the second direction, where the axial direction, circumferential direction, and radial direction of the rotating electric machine are defined as a first direction, a second direction, and a third direction, respectively, and a holding member formed of an electrically insulating resin and covering the plurality of bus bars, the plurality of bus bars extending in the first direction and electrically connected to a power source. The electrical connector includes a first bus bar, a second bus bar, and a third bus bar, each of which has a first connection portion, a second connection portion extending in the third direction and supplying power from the power source to the stator, and an intermediate portion extending in the second direction between the first connection portion and the second connection portion, and the retaining member has a first retaining portion covering the first bus bar and the second bus bar and interposed between the first bus bar and the second bus bar, and a second retaining portion covering the first retaining portion and the third bus bar, and the third bus bar abuts against the first retaining portion. Effect of the Invention

[0009] According to the present disclosure, misalignment of the bus bar can be suppressed. [Brief description of the drawings]

[0010] [Figure 1] FIG. 1 is a plan view showing an embodiment of a busbar module for a rotating electric machine, the busbar module being attached to a stator. [Diagram 2] FIG. 2 is a perspective view showing the bus bar module of FIG. [Diagram 3] FIG. 3 is a bottom view showing the bus bar module of FIG. [Figure 4] FIG. 4 is a perspective view showing a first bus bar and a second bus bar in the bus bar module of FIG. [Diagram 5] FIG. 5 is a perspective view showing a third bus bar in the bus bar module of FIG. [Figure 6] FIG. 6 is a perspective view showing a fourth bus bar in the bus bar module of FIG. [Figure 7] FIG. 7 is a perspective view showing a primary molded body of the bus bar module of FIG. [Figure 8] FIG. 8 is a bottom view showing a primary molded body of the bus bar module of FIG. [Figure 9] FIG. 9 is a cross-sectional view of the bus bar module of FIG. 1, showing a state in which a cavity of a first molding die is filled with molten resin. [Figure 10] FIG. 10 is an exploded perspective view showing the primary molded body, the third bus bar, and the fourth bus bar in the bus bar module of FIG. [Figure 11] FIG. 11 is a plan view showing a state in which a third bus bar and a fourth bus bar are attached to a primary molded body in the bus bar module of FIG. [Figure 12] FIG. 12 is a bottom view of the bus bar module of FIG. 1, showing a state in which a third bus bar and a fourth bus bar are attached to a primary molded body. [Figure 13] FIG. 13 is a cross-sectional view of the bus bar module of FIG. 1, showing a state in which the cavity of the second molding die is filled with molten resin. [Figure 14] FIG. 14 is a cross-sectional view of the bus bar module of FIG. 1, showing a state in which the cavity of the second molding die is filled with molten resin. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0011] [Description of the embodiments of the present disclosure] First, the embodiments of the present disclosure will be listed and described. The busbar module for a rotating electric machine according to the present disclosure includes: [1] A busbar module for a rotating electric machine electrically connected to a coil of a stator constituting a rotating electric machine, the busbar module comprising: a plurality of busbars arranged at intervals in the first direction and arranged side by side in the second direction, where the axial direction, circumferential direction, and radial direction of the rotating electric machine are defined as a first direction, a second direction, and a third direction, respectively; and a holding member formed of an electrically insulating resin and covering the plurality of busbars, the plurality of busbars having first connection portions extending in the first direction and electrically connected to a power source. the retaining member includes a first retaining portion that covers the first bus bar and the second bus bar and is interposed between the first bus bar and the second bus bar, and a second retaining portion that covers the first retaining portion and the third bus bar, and the third bus bar abuts against the first retaining portion.

[0012] According to this configuration, first, the first bus bar and the second bus bar are inserted into a first mold, and the cavity of the first mold is filled with molten resin to form a primary molded body composed of the first bus bar, the second bus bar, and the first holding portion. At this time, the distance between the bus bars can be made larger than when the cavity of the mold is filled with molten resin while the first bus bar, the second bus bar, and the third bus bar are inserted into the mold. This suppresses the occurrence of differences in the flow pressure of the molten resin. Therefore, the positional deviation of the first bus bar and the second bus bar is suppressed.

[0013] Next, with the primary molded body and the third bus bar inserted into the second mold, the cavity of the second mold is filled with molten resin to form a secondary molded body consisting of the primary molded body, the third bus bar, and the second holding portion. At this time, since the third bus bar abuts against the first holding portion, there is no gap between the third bus bar and the first holding portion. Therefore, the molten resin does not flow between the third bus bar and the first holding portion. This suppresses misalignment of the third bus bar compared to when molten resin is filled with a gap between the third bus bar and the first holding portion.

[0014] Therefore, misalignment of the bus bars can be suppressed. [2] It is preferable that the intermediate portion of the third bus bar is plate-shaped extending in the first direction and the second direction, and the first retaining portion has a base portion having an abutment surface against which one end face in the first direction of at least one of the first connection portion and the intermediate portion of the third bus bar abuts, and protrusions protruding from the base portion on both sides of the abutment surface in the third direction and sandwiching at least one of the first connection portion and the intermediate portion of the third bus bar.

[0015] With this configuration, when the secondary molded body is formed, the protrusion prevents the third bus bar from moving relative to the first holding portion, i.e., the primary molded body, in the third direction due to flow pressure of the molten resin, thereby further suppressing misalignment of the third bus bar.

[0016] [3] It is preferable that at least one of the first bus bar, the second bus bar, and the third bus bar has a through hole penetrating in the first direction, and the retaining member has a communication hole communicating with the through hole in the first direction.

[0017] For example, in a configuration in which the first bus bar and the second bus bar have through holes and the first holding portion has communication holes that communicate with these through holes, the following manufacturing method can be adopted. That is, when the first molding die is clamped, positioning pins are inserted into the through holes of the first bus bar and the second bus bar. In this state, molten resin is filled into the cavity of the first molding die. This makes it possible to further suppress misalignment of the first bus bar and the second bus bar. At this time, communication holes that communicate with each of the through holes are formed in the first holding portion.

[0018] Furthermore, for example, in a configuration in which the third bus bar has a through hole and the second holding portion has a communication hole that communicates with the through hole, the following manufacturing method can be adopted. That is, when the second molding die is clamped, a positioning pin is inserted into the through hole of the third bus bar. In this state, molten resin is filled into the cavity of the second molding die. This makes it possible to further suppress misalignment of the third bus bar. At this time, a communication hole that communicates with the through hole is formed in the second holding portion.

[0019] Therefore, according to the above configuration, it is possible to further suppress misalignment of at least one of the first bus bar, the second bus bar, and the third bus bar. [4] It is preferable that the first bus bar, the second bus bar, and the third bus bar each have the through hole.

[0020] According to this configuration, misalignment of the first bus bar, the second bus bar, and the third bus bar can be further suppressed. [5] It is preferable that the communicating hole has a first hole formed in the first retaining portion and a second hole formed in the second retaining portion, and the second hole communicates with the first hole in the first direction.

[0021] In a configuration in which the second hole formed in the second holding part is in communication with the first hole formed in the first holding part, the following manufacturing method can be adopted. That is, when the second mold is closed, a positioning pin is inserted into a through hole provided in at least one of the first bus bar and the second bus bar constituting the primary molded body and the first hole communicating with the through hole. Therefore, with the above configuration, the through hole used in forming the primary molded body and the first hole formed in the first holding part can be used in forming the secondary molded body.

[0022] [6] It is preferable that the plurality of bus bars include a fourth bus bar electrically connected to a neutral wire of the coil, and the first retaining portion has a base portion having a first abutment surface against which one end face in the first direction of at least one of the first connection portion and the intermediate portion of the third bus bar abuts, and a second abutment surface located opposite the first abutment surface in the first direction and against which the fourth bus bar abuts, and that the second retaining portion covers the fourth bus bar.

[0023] According to this configuration, a secondary molded body consisting of the primary molded body, the third bus bar, and the fourth bus bar, and the second holding portion is formed by filling the cavity of the second mold with molten resin while the primary molded body, the third bus bar, and the fourth bus bar are inserted into the second mold. At this time, since the fourth bus bar abuts against the first holding portion, there is no gap between the fourth bus bar and the first holding portion. Therefore, the molten resin does not flow between the fourth bus bar and the first holding portion. This makes it possible to suppress misalignment of the fourth bus bar compared to a case where molten resin is filled with a gap between the fourth bus bar and the first holding portion.

[0024] [7] It is preferable that the first connection portion of the third bus bar is located between the first connection portion of the first bus bar and the first connection portion of the second bus bar in both the second direction and the third direction, the first retaining portion covers the first connection portions of both the first bus bar and the second bus bar, the intermediate portion of the third bus bar extends from the first connection portion to one side in the second direction, and the third bus bar has an extending portion extending from a base end of the first connection portion to a side opposite the intermediate portion of the third bus bar in the second direction, and the intermediate portion of the third bus bar abuts in the third direction against a portion of the first retaining portion that covers one of the first bus bar and the second bus bar, and the extending portion abuts in the third direction against a portion of the first retaining portion that covers the other of the first bus bar and the second bus bar.

[0025] According to this configuration, the first holding portion is interposed between the first connection portions of both the first bus bar and the second bus bar and between the intermediate portion and the extending portion of the third bus bar, thereby electrically insulating the first bus bar and the second bus bar from the third bus bar.

[0026] Furthermore, when the secondary molded body is formed, the movement of the third bus bar relative to the first holding portion, i.e., the primary molded body, in the third direction due to the flow pressure of the molten resin is restricted by the portion of the first holding portion that covers the first connection portions of both the first and second bus bars, thereby further suppressing misalignment of the bus bars.

[0027] [Details of the embodiment of the present disclosure] Specific examples of the busbar module for a rotating electric machine according to the present disclosure will be described below with reference to the drawings. In each drawing, for convenience of explanation, some of the configuration may be exaggerated or simplified. Furthermore, the dimensional ratio of each part may differ between drawings. Note that the present disclosure is not limited to these examples, but is indicated by the claims, and is intended to include all modifications within the meaning and scope equivalent to the claims. In this specification, "orthogonal" does not only mean strictly orthogonal, but also includes approximately orthogonal within the scope of the effect of the present embodiment.

[0028] <Overall configuration of bus bar module 94> As shown in Figs. 1 to 3, a bus bar module 94 is used in a rotating electric machine 90 such as a motor generator in a hybrid vehicle or an electric vehicle.

[0029] The rotating electric machine 90 is composed of a cylindrical stator 91 including a stator core 92 in which a plurality of slots (not shown) are formed and coils 93 inserted into the slots, and a rotor (not shown) disposed radially inside the stator 91. In this embodiment, the rotating electric machine 90 is driven by three-phase AC. The coils 93 are composed of three phase coils corresponding to the three phases (U phase, V phase, and W phase).

[0030] The busbar module 94 is disposed at one axial end of the stator 91 and is electrically connected to the coil 93 . In the following description, the axial direction, circumferential direction, and radial direction of the rotary electric machine 90 will be referred to as a first direction X, a second direction Y, and a third direction Z, respectively.

[0031] In addition, in the first direction X, the side on which the busbar module 94 is arranged with respect to the stator 91 is referred to as one side X1 in the first direction, and the opposite side is referred to as the other side X2 in the first direction. In addition, in the third direction Z, the side of the central axis of the rotary electric machine 90 is referred to as the third direction inner side Z1, and the opposite side is referred to as the third direction outer side Z2.

[0032] The bus bar module 94 includes a first bus bar 10, a second bus bar 20, a third bus bar 30, and a fourth bus bar 40 electrically connected to the coil 93, a retaining member 50 covering each of the bus bars 10, 20, 30, and 40, and a temperature sensor 80.

[0033] The temperature sensor 80 detects the temperature of the coil 93 by detecting the temperature of a bus bar electrically connected to the coil 93, and includes a temperature detection unit 81 and an electric wire 82 extending from the temperature detection unit 81. The temperature detection unit 81 is provided with, for example, a thermistor. The temperature sensor 80 is provided at one end of the bus bar module 94 in the second direction Y.

[0034] Next, each component of the bus bar module 94 will be described in detail. <Configuration of First Bus Bar 10 and Second Bus Bar 20> As shown in FIG. 4, the first bus bar 10 and the second bus bar 20 are formed from a conductive metal plate material.

[0035] The first bus bar 10 and the second bus bar 20 are arranged in order from the other side to one side in the second direction Y. The first bus bar 10 and the second bus bar 20 are arranged side by side in the second direction Y with an interval therebetween.

[0036] In the following description, the side of the second bus bar 20 relative to the first bus bar 10 in the second direction Y will be referred to as the second direction one side Y1, and the opposite side will be referred to as the second direction other side Y2. The bus bars 10 and 20 have first connection portions 11 and 21 that are electrically connected to a power source (not shown) and second connection portions 12 and 22 that supply power from the power source to the stator 91.

[0037] Further, the bus bars 10, 20 have intermediate portions 13, 23 extending in the second direction Y between the first connection portions 11, 21 and the second connection portions 12, 22. The ends 13a, 23a of the intermediate portions 13, 23 on the other side Y2 in the second direction are bent at their tips and extend toward the inside Z1 in the third direction.

[0038] The first connection parts 11, 21 are provided at the ends of the intermediate parts 13, 23 on one side Y1 in the second direction. The first connection parts 11, 21 protrude from the end faces of the ends of the intermediate parts 13, 23 on the inner side Z1 in the third direction, and have rising tips extending to one side X1 in the first direction. The first connection parts 11, 21 are flat-plate shaped extending in the first direction X and in a direction perpendicular to both the first direction X and the third direction Z.

[0039] The second connection parts 12, 22 extend in the third direction Z from the ends 13a, 23a of the intermediate parts 13, 23. The second connection parts 12, 22 have flat plate parts 12a, 22a located on the end 13a, 23a side in the third direction Z, and rod-shaped terminal parts 12b, 22b located on the tip side. The terminal parts 12b, 22b protrude from the part located on the other side Y2 in the second direction of the end face of the flat plate parts 12a, 22a on the third direction inner side Z1. In this embodiment, the terminal part 12b is a part connected to a power line (not shown) of a coil corresponding to the U phase of the coil 93. The terminal part 22b is a part connected to a power line (not shown) of a coil corresponding to the W phase of the coil 93.

[0040] The flat plate portions 12a and 22a are provided with through holes 14 and 24 penetrating in the first direction X, respectively. <Configuration of third bus bar 30> As shown in FIG. 5, the third bus bar 30 is formed from a conductive metal plate material.

[0041] The third bus bar 30 has a first connection portion 31 electrically connected to a power source (not shown), and a second connection portion 32 that supplies electric power from the power source to the stator 91. In addition, the third busbar 30 has an intermediate portion 33 extending in the second direction Y between the first connection portion 31 and the second connection portion 32, and an extending portion 35 extending from the first connection portion 31 to the opposite side to the intermediate portion 33 in the second direction Y.

[0042] The first connection portion 31 has a flat plate shape extending in the first direction X and in a direction perpendicular to both the first direction X and the third direction Z. The intermediate portion 33 extends in the second direction Y from a portion of an end face of the first connecting portion 31 on the second direction side Y1 that is located closest to the other side X2 in the first direction. An end portion 33a of the intermediate portion 33 on the second direction side Y1 is bent toward the other side X2 in the first direction, and has a tip that extends toward the inside Z1 in the third direction.

[0043] The second connection portion 32 extends from an end portion 33a of the intermediate portion 33 toward the inside in the third direction Z1. The second connection portion 32 has a flat plate portion 32a located on the end portion 33a side in the third direction Z, and a rod-shaped terminal portion 32b located on the tip side. The terminal portion 32b protrudes from a portion of the end face of the flat plate portion 32a located on the inside in the third direction Z1, which is located closest to the other side Y2 in the second direction. In this embodiment, the terminal portion 32b is a portion that is connected to a power line (not shown) of a coil corresponding to the V phase among the coils 93.

[0044] The flat plate portion 32a is provided with a through hole 34 penetrating in the first direction X. The extending portion 35 extends in the second direction Y from a portion of an end face of the second direction side Y2 of the first connecting portion 31 that is located closest to the first direction side X2. An end portion 35a of the extending portion 35 on the second direction side Y2 is bent toward the first direction side X2, and has a tip that extends outward in the third direction Z2.

[0045] <Configuration of Fourth Bus Bar 40> As shown in FIG. 6, the fourth bus bar 40 is formed from a conductive metal plate material. The fourth bus bar 40 forms the neutral point of the coil 93 and has a main body portion 41 extending in the second direction Y and three third connection portions 43A, 43B, 43C protruding from the main body portion 41 and connected to the neutral wire (not shown) of the coil 93.

[0046] The end of the main body 41 on the one side Y1 in the second direction is provided with a folded-back portion 42 formed by folding back the tip. The folded portion 42 has a base end 42a extending in the second direction Y, a bent portion 42b bent from the tip of the base end 42a, and a tip end 42c extending from the tip of the bent portion 42b along the base end 42a.

[0047] An end face of the bent portion 42b on the first direction side X1 is a portion with which a tip end of the temperature detection portion 81 of the temperature sensor 80 abuts.

[0048] An end face of the bent portion 42b on the second direction side Y1 is provided with a recess 42d that is configured with a pair of projections that project in the second direction Y and into which a projection (not shown) formed on the temperature detection portion 81 fits.

[0049] The third connection portions 43A, 43B, and 43C are arranged in order from the other side Y2 in the second direction to the one side Y1 in the second direction. The third connection portions 43A, 43B, and 43C are arranged in the second direction Y at equal intervals.

[0050] The third connection portions 43A, 43B protrude from an end face on the inside in the third direction Z1 of the main body 41. The third connection portions 43A, 43B have a flat plate portion 43a located on the main body 41 side in the third direction Z, and a rod-shaped terminal portion 43b located on the tip side. The terminal portion 43b protrudes from a portion of the end face on the inside in the third direction Z1 of the flat plate portion 43a that is located furthest on the other side Y2 in the second direction.

[0051] The third connection portion 43C is provided at the tip of the tip portion 42c of the folded portion 42. The third connection portion 43C protrudes from an end face of the tip portion 42c on the third direction inner side Z1. The third connection portion 43C has a base portion 43c located on the tip portion 42c side and extending in the second direction Y, and a rod-shaped terminal portion 43d located on the tip side. The terminal portion 43d protrudes from the tip of the base portion 43c on the third direction inner side Z1. The third connection portion 43C is L-shaped overall.

[0052] In this embodiment, the terminal portions 43b and 43d are portions to be connected to a neutral wire (not shown) of the coil 93. The flat plate portions 43a of the third connection portions 43A and 43B are provided with through holes 44 penetrating in the first direction X.

[0053] <Basic configuration of holding member 50> As shown in FIGS. 2 to 8, the holding member 50 is made of an electrically insulating resin material, and covers the bus bars 10, 20, 30, 40 and the temperature sensor 80. As shown in FIG.

[0054] The retaining member 50 has a first retaining portion 51 that covers the first bus bar 10 and the second bus bar 20 and is interposed between the first and second bus bars 10, 20, and a second retaining portion 56 that covers the first retaining portion 51, the third bus bar 30, the fourth bus bar 40, and the temperature detection portion 81 of the temperature sensor 80.

[0055] The holding member 50 also has a plurality of communication holes 70 that communicate with the through holes 14, 24, 34, 44 in the first direction X. The communication holes 70 include a first hole 71 formed in the first holding portion 51 and a second hole 72 formed in the second holding portion 56.

[0056] Next, each component of the holding member 50 will be described in detail. <Configuration of first holding portion 51> As shown in Figures 4, 7 and 8, the first retaining portion 51 has a base portion 52, a first surrounding portion 53 covering the first connection portions 11, 21, a second surrounding portion 54 covering the second connection portions 12, 22, and a protrusion 60.

[0057] The base portion 52 extends in the second direction Y and covers the entire intermediate portions 13, 23 of the first bus bar 10 and the second bus bar 20 collectively. 7 and 10, the base portion 52 has a first abutment surface C1 against which end faces on the other side X2 in the first direction of each of the first connection portion 31, the intermediate portion 33, and the extending portion 35 of the third busbar 30 abut. The first abutment surface C1 is provided on an end face 52a of the base portion 52 on the one side X1 in the first direction.

[0058] 8 and 12, a fitting recess 55 into which the fourth bus bar 40 fits is formed in an end face 52b on the other side X2 in the first direction (the front side in the direction perpendicular to the paper surface of FIG. 8) of the base portion 52. A bottom surface of the fitting recess 55 constitutes a second abutment surface C2 with which the end face of the one side X1 in the first direction of the fourth bus bar 40 abuts.

[0059] 4 and 7, the first surrounding portion 53 extends from the base portion 52 toward the first direction side X1 and covers the base end sides of the first connection portions 11, 21. The tip sides of the first connection portions 11, 21 are exposed to the outside (see FIG. 7).

[0060] 4 and 8, the second surrounding portion 54 extends from the base portion 52 toward the inside in the third direction Z1 and covers the flat plate portions 12a, 22a of the second connection portions 12, 22. The terminal portions 12b, 22b of the second connection portions 12, 22 are exposed to the outside (see FIG. 8).

[0061] A first hole 71 is formed in each of the second surrounding portions 54. Each of the first holes 71 communicates with the through hole 14 of the first bus bar 10 and the through hole 24 of the second bus bar 20 in the first direction X.

[0062] 7, the protrusions 60 protrude from the base portion 52 to one side X1 in the first direction on both sides of the first contact surface C1 in the third direction Z. The protrusions 60 have a pair of first protrusions 61 located on the inner side Z1 in the third direction and a second protrusion 62 located on the outer side Z2 in the third direction.

[0063] The pair of first protrusions 61 protrude from an end face 52c on the inside in the third direction Z1 of the base portion 52. The first protrusions 61 are arranged at an interval from each other in the second direction Y. The base ends of the pair of first protrusions 61 in the first direction X are continuous with the outer surface of the second surrounding portion 54 that covers the second connection portion 22.

[0064] The second projection 62 projects in the first direction X from the end surface 52a of the base portion 52 and extends in the second direction Y. <Configuration of second holding portion 56> As shown in Figures 2 and 3, the second retaining portion 56 has a base portion 57, a third surrounding portion 58 that covers a portion of the third busbar 30, and a support portion 59 that supports the temperature detection portion 81 of the temperature sensor 80.

[0065] 2 to 8, the base portion 57 extends in the second direction Y and covers the ends 33a, 35a and a part of the second connection portion 32 of the third bus bar 30. The base portion 57 also covers the end face of the first holding portion 51 on the other side X2 in the first direction, and covers the main body portion 41, the folded portion 42, and parts of the third connection portions 43A, 43B, 43C of the fourth bus bar 40. In detail, the base portion 57 covers the flat portion 32a of the second connection portion 32, the flat portion 43a of the third connection portions 43A, 43B, and the base portion 43c of the third connection portion 43C. The terminal portions 32b, 43b, 43d of the bus bars 30, 40 are exposed to the outside (see FIGS. 2 and 3).

[0066] As shown in FIG. 3, the base portion 57 has four second holes 72 formed therein. 2 to 6, each second hole 72 communicates in the first direction X with the through hole 24 of the second bus bar 20, the through hole 34 of the third bus bar 30, and the two through holes 44 of the fourth bus bar 40. The second hole 72 communicating with the through hole 24 also communicates with the first hole 71 in the first direction X.

[0067] 2 and 5, the third surrounding portion 58 extends from the base portion 57 to the first side X1 in the first direction. The third surrounding portion 58 covers the base end side of the first connection portion 31 of the third busbar 30, and the intermediate portion 33 and the extending portion 35 extending from the first connection portion 31, the portions extending in both the first direction X and the second direction Y. The tip side of the first connection portion 31 is exposed to the outside (see FIG. 2).

[0068] 2 and 6, the support portion 59 is provided at an end portion on one side Y1 in the second direction of the base portion 57. The support portion 59 collectively covers the bent portion 42b and the tip portion of the temperature detection portion 81 in a state where the tip portion of the temperature detection portion 81 of the temperature sensor 80 abuts against the bent portion 42b of the folded-back portion 42 (see FIG. 2).

[0069] A plurality of holes 73 are formed in the second holding portion 56. The plurality of holes 73 are provided at positions that do not overlap with the second holes 72 in the first direction X. <Method of Manufacturing Busbar Module 94> Next, a manufacturing method of the bus bar module 94 will be described with reference to Fig. 9 to Fig. 14. Fig. 9 is a diagram corresponding to the cross-sectional view taken along line 9-9 in Fig. 8, and Figs. 13 and 14 are diagrams corresponding to the cross-sectional views taken along lines 13-13 and 14-14 in Fig. 11.

[0070] 9, positioning pin 114 is inserted into through hole 24 of second bus bar 20. Furthermore, although not shown, positioning pin 114 is inserted into through hole 14 of first bus bar 10. In this state, upper die 111 and lower die 112 of first molding die 110 are clamped. As a result, first bus bar 10 and second bus bar 20 inserted into first molding die 110 are positioned with respect to cavity 113.

[0071] Next, molten resin R1 is filled into cavity 113 of first molding die 110. This forms a primary molded body 94a that is composed of first bus bar 10, second bus bar 20, and first holding portion 51. At this time, first holes 71 that communicate with each of through holes 14, 24 are formed in first holding portion 51.

[0072] Next, as shown in FIG. 10, the third bus bar 30 and the fourth bus bar 40 are attached to the primary molded body 94a. 10 and 11, in order to attach the third bus bar 30 to the end surface 52a of the base portion 52, the first connection portion 31 of the third bus bar 30 is inserted between a pair of first projections 61 and second projections 62 protruding from the base portion 52. Then, the insertion of the third bus bar 30 is continued until the end surfaces on the other side X2 in the first direction of each of the first connection portion 31, the intermediate portion 33, and the extending portion 35 of the third bus bar 30 abut against the first abutment surface C1 of the base portion 52. In this way, the third bus bar 30 is attached to the primary molded body 94a.

[0073] At this time, the first connection portion 31 of the third bus bar 30 abuts against the pair of first protrusions 61 and second protrusions 62. The first connection portion 31 of the third bus bar 30 is located between the first connection portion 11 of the first bus bar 10 and the first connection portion 21 of the second bus bar 20 in both the second direction Y and the third direction Z. The middle portion 33 of the third bus bar 30 abuts against one of the two first surrounding portions 53 that covers the first connection portion 21 of the second bus bar 20 from the outside Z2 in the third direction. The extension portion 35 of the third bus bar 30 abuts against one of the two first surrounding portions 53 that covers the first connection portion 11 of the first bus bar 10 from the inside Z1 in the third direction.

[0074] 10 and 12, the fourth bus bar 40 is attached to the fitting recess 55 formed in the end face 52b of the other side X2 in the first direction of the base portion 52. This positions the fourth bus bar 40 at a regular attachment position relative to the primary molded body 94a. At this time, the end face of the one side X1 in the first direction of the fourth bus bar 40 is in contact with the second contact surface C2 (see FIG. 8) of the base portion 52.

[0075] At this time, the third bus bar 30, the first bus bar 10, the second bus bar 20, and the fourth bus bar 40 are arranged at intervals from each other in the first direction X (see FIGS. 13 and 14).

[0076] Next, as shown in FIG. 13, a positioning pin 124 is inserted into the through hole 24 of the second bus bar 20. Although not shown, the positioning pin 124 is inserted into the through holes 34, 44 of the third bus bar 30 and the fourth bus bar 40. In this state, as shown in FIG. 13 and FIG. 14, the upper mold 121 and the lower mold 122 of the second molding die 120 are clamped. At this time, the primary molded body 94a, the third bus bar 30, the fourth bus bar 40, and the temperature detection unit 81 are fixed by a plurality of jigs (not shown) that sandwich the bus bars 10, 20, 30, 40, and the temperature detection unit 81 from both sides in the first direction X. As a result, the primary molded body 94a, the third bus bar 30, the fourth bus bar 40, and the temperature detection unit 81 inserted into the second molding die 120 are positioned with respect to the cavity 123.

[0077] Next, molten resin R2 is filled into cavity 123 of second molding die 120. This forms secondary molded body 94b composed of primary molded body 94a, third bus bar 30, fourth bus bar 40, second holding portion 56, and temperature sensor 80. At this time, as shown in Fig. 13, second holding portion 56 is formed with through hole 24, first hole 71 communicating with through hole 24, and second holes 72 communicating with through hole 34 and two through holes 44, respectively.

[0078] As shown in FIG. 2, the second holding portion 56 has a plurality of holes 73 formed therein by the above-mentioned plurality of jigs (not shown). At this time, the second connection portion 12, the third connection portion 43A, the second connection portion 22, the third connection portion 43B, the second connection portion 32, and the third connection portion 43C are arranged in sequence from the other side Y2 in the second direction to the one side Y1 in the second direction, and are arranged at equal intervals from each other in the second direction Y.

[0079] Next, the operation of this embodiment will be described. First, with the first bus bar 10 and the second bus bar 20 inserted into the first molding die 110, the cavity 113 of the first molding die 110 is filled with molten resin R1. This forms a primary molded body 94a consisting of the first bus bar 10, the second bus bar 20, and the first holding portion 51. At this time, the distance between the bus bars 10, 20 can be made larger than when the cavity of the molding die is filled with molten resin with the first bus bar 10, the second bus bar 20, the third bus bar 30, and the fourth bus bar 40 inserted into the molding die. This suppresses the occurrence of differences in the flow pressure of the molten resin R1.

[0080] Next, in a state where the primary molded body 94a, the third bus bar 30, and the fourth bus bar 40 are inserted into the second molding die 120, the cavity 123 of the second molding die 120 is filled with molten resin R2. As a result, a secondary molded body 94b consisting of the primary molded body 94a, the third bus bar 30, the fourth bus bar 40, and the second holding portion 56 is formed. At this time, since the third bus bar 30 and the fourth bus bar 40 are in contact with the first holding portion 51, there is no gap between the third bus bar 30 and the first holding portion 51 and between the fourth bus bar 40 and the first holding portion 51. Therefore, the molten resin R2 does not flow between the third bus bar 30 and the first holding portion 51 and between the fourth bus bar 40 and the first holding portion 51.

[0081] Next, the effects of this embodiment will be described. (1) The retaining member 50 has a first retaining portion 51 that covers the first bus bar 10 and the second bus bar 20 and is interposed between the first bus bar 10 and the second bus bar 20, and a second retaining portion 56 that covers the first retaining portion 51, the third bus bar 30, and the fourth bus bar 40. The third bus bar 30 abuts against the first retaining portion 51.

[0082] This configuration provides the above-mentioned advantages, and therefore, positional deviation of the bus bars 10, 20, and 30 can be suppressed. (2) The intermediate portion 33 of the third busbar 30 is plate-shaped extending in the first direction X and the second direction Y. The first retaining portion 51 has a base portion 52 having a first abutment surface C1 against which end faces on the other side X2 in the first direction of the first connecting portion 31, the intermediate portion 33, and the extending portion 35 of the third busbar 30 abut. The first retaining portion 51 also has protrusions 60 that protrude from the base portion 52 on both sides of the first abutment surface C1 in the third direction Z and sandwich the first connecting portion 31 of the third busbar 30.

[0083] According to this configuration, when the secondary molded body 94b is formed, the protrusions 60 restrict the third bus bar 30 from moving relative to the first holding portion 51, i.e., the primary molded body 94a, in the third direction Z due to the flow pressure of the molten resin R2. This further reduces the positional deviation of the third bus bar 30.

[0084] (3) The first bus bar 10, the second bus bar 20, the third bus bar 30, and the fourth bus bar 40 respectively have through holes 14, 24, 34, and 44. The holding member 50 has a communication hole 70 that communicates with the through holes 14, 24, 34, and 44 in the first direction X.

[0085] According to this configuration, when the first molding die 110 is clamped, the positioning pins 114 are inserted into the through holes 14, 24 of the first bus bar 10 and the second bus bar 20. In this state, the molten resin R1 is filled into the cavity 113 of the first molding die 110. This makes it possible to further suppress misalignment of the first bus bar 10 and the second bus bar 20. At this time, the first holding portion 51 has communication holes 70 that communicate with the through holes 14, 24.

[0086] Furthermore, when the second molding die 120 is clamped, positioning pins 124 are inserted into the through holes 34, 44 of the third bus bar 30 and the fourth bus bar 40. In this state, molten resin R2 is filled into the cavity 123 of the second molding die 120. This makes it possible to further suppress misalignment of the third bus bar 30 and the fourth bus bar 40. At this time, a communication hole 70 communicating with the through holes 34, 44 is formed in the second holding portion 56.

[0087] Therefore, misalignment of the first bus bar 10, the second bus bar 20, the third bus bar 30, and the fourth bus bar 40 can be further suppressed. (4) The communication hole 70 has a plurality of first holes 71 formed in the first holding portion 51 and a plurality of second holes 72 formed in the second holding portion 56. One of the plurality of second holes 72 communicates with the first hole 71, which communicates with the through hole 24, in the first direction X.

[0088] According to this configuration, when the second molding die 120 is clamped, the positioning pin 124 is inserted into the through hole 24 provided in the second bus bar 20 constituting the primary molded body 94a and the first hole 71 communicating with the through hole 24. Therefore, the through hole 24 and the first hole 71 formed in the first holding portion 51 used when forming the primary molded body 94a can be used when forming the secondary molded body 94b.

[0089] (5) The first retaining portion 51 includes a base portion 52. The base portion 52 has a first contact surface C1 against which end faces on the other side X2 in the first direction of each of the first connecting portion 31, the intermediate portion 33, and the extending portion 35 of the third bus bar 30 abut. The base portion 52 is located on the opposite side to the first contact surface C1 in the first direction X, and has a second contact surface C2 against which the fourth bus bar 40 abuts. The second retaining portion 56 covers the fourth bus bar 40.

[0090] According to this configuration, the primary molded body 94a, the third bus bar 30, and the fourth bus bar 40 are inserted into the second molding die 120, and the cavity 123 of the second molding die 120 is filled with molten resin R2 to form the secondary molded body 94b. At this time, since the fourth bus bar 40 is in contact with the first holding portion 51, there is no gap between the fourth bus bar 40 and the first holding portion 51. Therefore, the molten resin R2 does not flow between the fourth bus bar 40 and the first holding portion 51. As a result, it is possible to suppress misalignment of the fourth bus bar 40 compared to the case where the molten resin R2 is filled in a state where there is a gap between the fourth bus bar 40 and the first holding portion 51.

[0091] (6) The first connection portion 31 of the third bus bar 30 is located between the first connection portion 11 of the first bus bar 10 and the first connection portion 21 of the second bus bar 20 in both the second direction Y and the third direction Z. The first surrounding portion 53 of the first holding portion 51 covers the first connection portions 11 of both the first bus bar 10 and the second bus bar 20. The middle portion 33 of the third bus bar 30 extends from the first connection portion 31 to one side Y1 in the second direction. The third bus bar 30 has an extension portion 35 that extends from a base end of the first connection portion 31 to a side opposite to the middle portion 33 of the third bus bar 30 in the second direction Y. The middle portion 33 of the third bus bar 30 abuts in the third direction Z against the first surrounding portion 53 of the first holding portion 51 that covers the first connection portion 21 of the second bus bar 20. The extending portion 35 abuts in the third direction Z against a first surrounding portion 53 of the first holding portion 51 that covers the first connection portion 11 of the first busbar 10 .

[0092] According to this configuration, the first surrounding portion 53 of the first holding portion 51 is interposed between the first connection portions 11 of both the first bus bar 10 and the second bus bar 20 and the intermediate portion 33 and the extending portion 35 of the third bus bar 30. Therefore, the first bus bar 10 and the second bus bar 20 are electrically insulated from the third bus bar 30.

[0093] Furthermore, when the secondary molded body 94b is formed, the movement of the third bus bar 30 relative to the primary molded body 94a in the third direction Z due to the flow pressure of the molten resin R2 is restricted by the first surrounding portion 53 covering the first connection portions 11, 21. Therefore, the positional deviation of the third bus bar 30 can be further suppressed.

[0094] <Example of change> This embodiment can be modified as follows: This embodiment and the following modifications can be combined with each other to the extent that there is no technical contradiction.

[0095] The temperature sensor 80 is not limited to being provided at the end of the busbar module 94 on the one side Y1 in the second direction as illustrated in this embodiment, and the location thereof may be changed as appropriate depending on the mounting requirements of the busbar module 94 on the stator 91. For example, the temperature sensor 80 may be provided at the end of the busbar module 94 on the other side Y2 in the second direction, or may be provided in the center of the busbar module 94 in the second direction Y.

[0096] The temperature sensor 80 may be omitted. In this case, the support portion 59 can be omitted from the second holding portion 56. The shapes of the bus bars 10, 20, 30, 40 are not limited to those exemplified in this embodiment, and may be appropriately changed in accordance with the requirements for mounting on the stator 91. For example, the extension portion 35 may be omitted from the third bus bar 30, and the folded-back portion 42 may be omitted from the fourth bus bar 40. In conjunction with such changes, the arrangement of the second connection portions 12, 22, 32 and the third connection portions 43A, 43B, 43C of the bus bar module 94 may be appropriately changed.

[0097] The number of the fourth bus bars 40 is not limited to one as illustrated in the present embodiment, and may be, for example, two or more. Also, the fourth bus bars 40 may be omitted. In this case, the fitting recess 55 can be omitted from the end surface 52b of the first holding portion 51.

[0098] The second holding portion 56 may have a second hole 72 communicating in the first direction X with the through hole 14 and the first hole 71 communicating with the through hole 14. In this case, the through hole 24 and the second hole 72 communicating in the first direction X with the first hole 71 communicating with the through hole 24 can be omitted from the second holding portion 56.

[0099] The second holding portion 56 is not limited to having the second hole 72 communicating with the first hole 71 in the first direction X as exemplified in this embodiment. In other words, the second hole 72 communicating with the first hole 71 in the first direction X may be omitted from the second holding portion 56.

[0100] The number and arrangement of the through holes 14 , 24 , 34 , 44 are not limited to those exemplified in this embodiment, and may be changed as appropriate in accordance with the shape of each bus bar 10 , 20 , 30 , 40 . The communication hole 70 is not limited to having the second hole 72. That is, the second hole 72 may be omitted from the second holding portion 56. In this case, the through holes 34, 44 can be omitted from the third bus bar 30 and the fourth bus bar 40. In this case, when forming the secondary molded body 94b, for example, the third bus bar 30 and the fourth bus bar 40 may be sandwiched by a jig from both sides in the first direction X. At this time, the hole 73 is formed in the second holding portion 56 by the jig. Note that even in such a case, it is preferable that the hole 73 is provided at the same position as the original second hole 72. With this configuration, it is possible to suppress the second connection portion 32 and the third connection portions 43A, 43B, 43C of the third bus bar 30 and the fourth bus bar 40 from being shifted from their normal positions.

[0101] The first hole 71 may be omitted. In this case, the through holes 14, 24 can be omitted from the first bus bar 10 and the second bus bar 20. In this case, when forming the primary molded body 94a, for example, the first bus bar 10 and the second bus bar 20 may be clamped by a jig from both sides in the first direction X. At this time, a hole 73 is formed in the first holding portion 51 by the jig. Note that even in this case, the hole 73 is preferably provided at the same position as the original first hole 71. With this configuration, it is possible to prevent the second connection portions 12, 22 of the first bus bar 10 and the second bus bar 20 from being shifted from their normal positions.

[0102] The holes 73 may be omitted from the holding member 50. Specifically, after the holding member 50 is molded, the holes 73 may be filled with another resin member. The shape of the protrusion 60 is not limited to the shape exemplified in this embodiment. For example, the protrusion 60 may have one first protrusion 61, or may have multiple second protrusions 62 arranged at intervals in the second direction Y.

[0103] The number of protrusions 60 is not limited to one as exemplified in this embodiment. For example, a plurality of protrusions 60 may be arranged at intervals along the extending direction of the first contact surface C1. In this case, the protrusions 60 are not limited to those sandwiching only the first connection portion 31 of the third bus bar 30 from both sides in the third direction Z, but may be those sandwiching at least one of the first connection portion 31 and the intermediate portion 33 of the third bus bar 30 from both sides in the third direction Z.

[0104] The first abutment surface C1 is not limited to the surface that abuts on the end surfaces on the other side X2 in the first direction of the first connecting portion 31, the intermediate portion 33, and the extending portion 35 of the third busbar 30 as illustrated in the present embodiment. For example, the first abutment surface C1 may be a surface that abuts on at least one of the first connecting portion 31 and the intermediate portion 33.

[0105] The arrangement of the multiple bus bars is not limited to that exemplified in this embodiment, and can be changed as appropriate according to the mounting requirements for the stator 91. Even in this case, it is sufficient that the multiple bus bars are arranged at intervals from each other in the first direction X and are arranged side by side in the second direction Y. [Explanation of symbols]

[0106] C1 1st contact surface C2 Second contact surface R1, R2 Molten resin X 1st direction X1 One side X2 Other side Y Second direction Y1 One side Y2 other side Z 3rd direction Z1 inside Z2 outside 10 First bus bar 11 First connection part 12 Second connection part 12a Flat plate part 12b Terminal section 13 Middle section 13a End 14 Through hole 20 2nd bus bar 21 First connection part 22 Second connection part 22a Flat plate part 22b Terminal section 23 Middle Section 23a End 24 Through hole 30 3rd bus bar 31 First connection part 32 Second connection part 32a Flat plate part 32b Terminal section 33 Middle Section 33a end 34 Through hole 35 Extension 35a end 40 4th bus bar 41 Main body 42 Folded part 42a Proximal end 42b Bent part 42c Tip 42d Recess 43A, 43B, 43C 3rd connection part 43a Flat plate part 43b Terminal section 43c base 43d Terminal section 44 Through hole 50 Retaining member 51 1st holding part 52 Base 52a End face 52b End face 52c end face 53 First Enclosure 54 Second Enclosure 55 Fitting recess 56 Second holding part 57 Base 58 Third Enclosure 59 Support part 60 protrusions 61 1st protrusion 62 2nd protrusion 70 Communication hole 71 Hole 1 72 2nd hole 73 holes 80 Temperature Sensor 81 Temperature detection unit 82 Electric wire 90 Rotating Electric Machine 91 Stator 92 Stator core 93 Coil 94 Busbar module 94a Primary mold body 94b Secondary mold body 110 1st mold 111 Upper mold 112 Lower mold 113 Cavity 114 pin 120 Second mold 121 Upper mold 122 Lower mold 123 Cavity 124 pin

Claims

1. A busbar module for a rotating electric machine, electrically connected to a coil of a stator constituting the rotating electric machine, When the axial direction, the circumferential direction, and the radial direction of the rotating electric machine are defined as a first direction, a second direction, and a third direction, respectively, a plurality of bus bars arranged at intervals from each other in the first direction and arranged side by side in the second direction; a holding member formed of an electrically insulating resin and covering the plurality of bus bars, The plurality of bus bars include a first connection portion extending in the first direction and electrically connected to a power source; a second connection portion extending in the third direction and supplying electric power from the power source to the stator; a first bus bar, a second bus bar, and a third bus bar each having an intermediate portion extending in the second direction between the first connection portion and the second connection portion, The holding member is a first holding portion covering the first bus bar and the second bus bar and interposed between the first bus bar and the second bus bar; a second holding portion covering the first holding portion and the third bus bar, the third bus bar abuts against the first holding portion, the plurality of bus bars includes a fourth bus bar electrically connected to a neutral wire of the coil, the first holding portion includes a base portion having a first contact surface against which one end surface in the first direction of at least one of the first connection portion and the intermediate portion of the third bus bar comes into contact, and a second contact surface located on the opposite side to the first contact surface in the first direction and against which the fourth bus bar comes into contact, the second holding portion covers the fourth bus bar, a protrusion is formed on a first contact surface of the first holding portion on an inner side in the third direction to sandwich the third bus bar, a fitting recess with which the fourth bus bar abuts is formed on a second contact surface of the first holding portion, and the fitting recess has a recess on an outer side in the third direction that abuts against a protrusion of the fourth bus bar; A busbar module for rotating electrical machines.

2. the intermediate portion of the third bus bar has a plate shape extending in the first direction and the second direction, The first holding portion is a base portion having a contact surface against which one end surface in the first direction of at least one of the first connection portion and the intermediate portion of the third bus bar is in contact; the projections protruding from the base portion on both sides of the abutment surface in the third direction and sandwiching at least one of the first connection portion and the intermediate portion of the third bus bar, The busbar module for a rotating electric machine according to claim 1 .

3. At least one of the first bus bar, the second bus bar, and the third bus bar has a through hole penetrating in the first direction, The holding member has a communication hole communicating with the through hole in the first direction. The busbar module for a rotating electric machine according to claim 1 or 2.

4. The first bus bar, the second bus bar, and the third bus bar each have the through hole. The busbar module for a rotating electric machine according to claim 3 .

5. the communication hole has a first hole formed in the first holding portion and a second hole formed in the second holding portion, The second hole communicates with the first hole in the first direction. The busbar module for a rotating electric machine according to claim 3 or 4.

6. the first connection portion of the third bus bar is located between the first connection portion of the first bus bar and the first connection portion of the second bus bar in both the second direction and the third direction, the first holding portion covers the first connection portions of both the first bus bar and the second bus bar, The intermediate portion of the third bus bar extends from the first connection portion to one side in the second direction, the third bus bar has an extension portion extending from a base end of the first connection portion to a side opposite to the intermediate portion of the third bus bar in the second direction, the intermediate portion of the third bus bar abuts against a portion of the first holding portion that covers one of the first bus bar and the second bus bar in the third direction, the extending portion is in contact with a portion of the first holding portion that covers the other of the first bus bar and the second bus bar in the third direction. The busbar module for a rotating electric machine according to any one of claims 1 to 5.

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