Motor device

Abstract

To provide a motor device capable of reducing operating noise while improving assembly.SOLUTION: A ground terminal 70, through which electrical noise generated by a rotation of a rotating shaft 39 flows, is provided between a motor case and a gear case 51, and first to third fixed parts FP1 to FP3 are provided between the motor case and the gear case 51, which are arranged around the rotating shaft 39 and consist of first and third motor case side abutment surfaces and first to third gear case side abutment surfaces GF1 to GF3 that abut against each other. The ground terminal 70 is arranged only between the second and third fixed parts FP2 and FP3, which form the shortest line segment (the second motor case side line segment and the second gear case side line segment GL2) among the line segments connecting the first to third fixed parts FP1 to FP3 adjacent to each other in the circumferential direction of the rotating shaft 39 (the first to third motor case side line segments and the first to third gear case side line segments GL1 to GL3).SELECTED DRAWING: Figure 7

Description

Technical Field

[0001] The present invention relates to a motor device including a rotating shaft and a gear rotated by the rotating shaft.

Background Art

[0002] For example, Patent Document 1 describes an electric motor including an armature shaft, a worm rotated by the armature shaft, and a worm wheel rotated by the worm. The armature shaft is housed in a yoke, and the worm and the worm wheel are housed in a casing. An annular contact plate is sandwiched between the yoke and the casing, and the contact plate has a function of releasing electric noise transmitted to the armature shaft to the ground.

Prior Art Documents

Patent Documents

[0003]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0004] However, in the technique described in Patent Document 1, if there are variations in the forming accuracy of the contact plate or variations in the tightening torque of the screws that fix the yoke and the casing to each other, the axis of the armature shaft and the axis of the worm may deviate, resulting in a problem that the operating noise increases.

[0005] An object of the present invention is to provide a motor device capable of reducing the operating noise while improving the assemblability.

Means for Solving the Problems

[0006] In one aspect of the present invention, there is provided a motor device including a rotating shaft and a gear rotated by the rotating shaft, the motor device comprising: a motor case for housing the rotating shaft; a gear case for housing the gear; and a conductive member sandwiched between the motor case and the gear case through which electrical noise generated by the rotation of the rotating shaft flows. Between the motor case and the gear case, at least three fixing portions each formed of a pair of abutting surfaces arranged around the rotating shaft and abutting against each other are provided, and the conductive member is disposed only between the fixing portions that form the shortest line segment among the line segments connecting the adjacent fixing portions in the circumferential direction of the rotating shaft.

Advantages of the Invention

[0007] According to the present invention, it is possible to realize a motor device capable of reducing the operating noise while improving the assemblability.

Brief Description of the Drawings

[0008]

Figure 1

Figure 2

Figure 3

Figure 4

Figure 5

Figure 6

Figure 7

Figure 8

Figure 9

Figure 10

Figure 11

Figure 12

Figure 13

Figure 14

Embodiments for Carrying Out the Invention

[0009] [Embodiment 1] Hereinafter, Embodiment 1 of the present invention will be described in detail with reference to the drawings.

[0010] FIG. 1 is a schematic diagram of a sunroof device installed on the roof of a vehicle, FIG. 2 is a perspective view showing the output gear side of the sunroof motor, FIG. 3 is a perspective view showing the cover member side of the sunroof motor, FIG. 4 is a cross-sectional view of the sunroof motor along the axial direction of the rotating shaft, FIG. 5 is a perspective view of the motor case seen from the flange portion side, FIG. 6 is a perspective view of the gear case seen from the motor housing portion side, FIG. 7 is a plan view of the gear case seen from the motor housing portion side, FIG. 8 is a view taken along arrow A in FIG. 6, and FIG. 9 is a perspective view showing the ground terminal alone.

[0011] [Overview of the Sunroof Device] As shown in FIG. 1, the sunroof device 10 includes a roof panel 11. The roof panel 11 opens and closes a roof opening 14 formed in the roof 13 of the vehicle 12. A pair of shoes 15a and 15b are respectively fixed to both sides in the vehicle width direction (the upper and lower sides in FIG. 1) of the roof panel 11.

[0012] In addition, guide rails 16 extending in the front-rear direction of the vehicle 12 (the left-right direction in FIG. 1) are respectively fixed to both sides in the vehicle width direction of the roof opening 14 in the roof 13. Then, the pair of shoes 15a and 15b are respectively guided by the pair of guide rails 16, and the roof panel 11 moves in the front-rear direction of the vehicle 12.

[0013] Furthermore, one end of each of the geared drive cables 17a and 17b is connected to a pair of shoes 15b disposed on the rear side (the right side in FIG. 1) of the vehicle 12. On the other hand, the other ends of the pair of drive cables 17a and 17b are routed to the front side (the left side in FIG. 1) of the vehicle 12 from the roof opening 14.

[0014] Also, inside the roof 13 between the windshield FG and the roof opening 14 in the longitudinal direction of the vehicle 12, a sunroof motor 20 is installed. And the other ends of the pair of drive cables 17a and 17b are engaged with an output gear 57a provided on the sunroof motor 20.

[0015] Thus, when the sunroof motor 20 is driven, the pair of drive cables 17a and 17b move in the longitudinal direction thereof in opposite directions to each other. Therefore, the roof panel 11 is pushed and pulled by the pair of drive cables 17a and 17b via the pair of shoes 15b to open and close the roof opening 14.

[0016] Note that the sunroof motor 20 corresponds to the motor device in the present invention.

[0017] [Sunroof motor] As shown in FIGS. 2 to 4, the sunroof motor 20 is formed in a flat substantially rectangular parallelepiped shape, whereby it can be installed inside the narrow roof 13 (see FIG. 1). The sunroof motor 20 includes an electric motor unit 30 and a speed reduction mechanism unit 50, and these electric motor unit 30 and speed reduction mechanism unit 50 are fixed to each other by a total of three fixing screws FS.

[0018] Here, in the present embodiment, the electric motor unit 30 employs a brushless motor. However, as the electric motor unit 30, a brushed electric motor can also be employed.

[0019] [Motor case] As shown in FIGS. 2 to 5, the electric motor unit 30 includes a motor case 31 that forms its outer shell. The motor case 31 is made of metal and is formed into a bottomed cylindrical shape by deep drawing a steel plate.

[0020] Inside the motor case 31, the proximal end side in the axial direction of the rotating shaft 39 (the right side in FIG. 4) is rotatably accommodated. The motor case 31 has a side wall portion 31a whose cross section along the direction orthogonal to the axial direction of the rotating shaft 39 is formed in a substantially regular hexagon. Further, a stepped bottom wall portion 31b is integrally provided on one axial side (the right side in FIG. 4) of the side wall portion 31a.

[0021] Furthermore, a motor case side opening 31c is provided on the other axial side (the left side in FIG. 4) of the side wall portion 31a. Also, a flange portion 31d is integrally provided on the other axial side of the side wall portion 31a so as to surround the motor case side opening 31c.

[0022] [Flange portion] As shown in FIG. 5, the flange portion 31d extends in a direction orthogonal to the axial direction of the rotating shaft 39 and is disposed around the motor case side opening 31c. Specifically, the flange portion 31d is formed in a substantially rectangular shape when viewed from the axial direction of the rotating shaft 39. And at the four corner portions forming the flange portion 31d, a first motor case side corner portion 32, a second motor case side corner portion 33, a third motor case side corner portion 34, and a motor case side abutting portion 35 are respectively provided.

[0023] The first motor case side corner portion 32 has a first motor case side abutting surface MF1 (see the shaded portion in FIG. 5) on the side opposite to the bottom wall portion 31b side in the axial direction of the motor case 31 (the gear case 51 side). The first motor case side abutting surface MF1 is a portion that abuts against the first gear case side abutting surface GF1 (see FIGS. 6 and 7) of the gear case 51 in the axial direction of the rotating shaft 39. And a first screw insertion hole 32a through which a fixing screw FS is inserted is provided in the first motor case side corner portion 32.

[0024] The second motor case side corner portion 33 has a second motor case side abutting surface MF2 (see the shaded portion in FIG. 5) on the side opposite to the bottom wall portion 31b side (gear case 51 side) in the axial direction of the motor case 31. The second motor case side abutting surface MF2 is a portion that abuts against the second gear case side abutting surface GF2 (see FIGS. 6 and 7) of the gear case 51 in the axial direction of the rotation shaft 39. And, a second screw insertion hole 33a through which the fixing screw FS is inserted is provided in the second motor case side corner portion 33.

[0025] The third motor case side corner portion 34 has a third motor case side abutting surface MF3 (see the shaded portion in FIG. 5) on the side opposite to the bottom wall portion 31b side (gear case 51 side) in the axial direction of the motor case 31. The third motor case side abutting surface MF3 is a portion that abuts against the third gear case side abutting surface GF3 (see FIGS. 6 and 7) of the gear case 51 in the axial direction of the rotation shaft 39. And, a third screw insertion hole 34a through which the fixing screw FS is inserted is provided in the third motor case side corner portion 34.

[0026] Note that the total of three first, second, and third motor case side abutting surfaces MF1, MF2, and MF3 provided on the flange portion 31d of the motor case 31 are provided between the motor case 31 and the gear case 51 and respectively correspond to the abutting surfaces in the present invention.

[0027] Also, the motor case side abutting portion 35 is a portion that abuts against the gear case side abutting portion 65 (see FIGS. 6 and 7) of the gear case 51 in the axial direction of the rotation shaft 39. And, the motor case side abutting portion 35 is disposed at a position facing the second motor case side corner portion 33 with the motor case side opening 31c as the center.

[0028] Here, the flange portion 31d extends accurately without distortion in a direction orthogonal to the axial direction of the motor case 31 (the left - right direction in FIG. 4). Specifically, after forming the motor case 31 by deep drawing, the flatness of the flange portion 31d is enhanced by pressing the flange portion 31d again (secondary processing). As a result, the first, second, and third motor - case - side abutting surfaces MF1, MF2, MF3 and the motor - case - side abutting portion 35 can be abutted against the gear case 51 without rattling. Therefore, the motor case 31 and the gear case 51 can be arranged coaxially and straight with respect to each other.

[0029] And, as shown in FIG. 5, the first motor - case - side line segment ML1 connecting the first motor - case - side abutting surface MF1 with the first screw insertion hole 32a disposed at the center and the second motor - case - side abutting surface MF2 with the second screw insertion hole 33a disposed at the center extends in the width direction of the sunroof motor 20 (the up - down direction in FIG. 4).

[0030] Also, the second motor - case - side line segment ML2 connecting the second motor - case - side abutting surface MF2 with the second screw insertion hole 33a disposed at the center and the third motor - case - side abutting surface MF3 with the third screw insertion hole 34a disposed at the center extends in the thickness direction of the sunroof motor 20 (the depth direction in FIG. 4).

[0031] Furthermore, the third motor - case - side line segment ML3 connecting the first motor - case - side abutting surface MF1 with the first screw insertion hole 32a disposed at the center and the third motor - case - side abutting surface MF3 with the third screw insertion hole 34a disposed at the center extends across the substantially axial center of the motor case 31, that is, the substantially central portion of the motor - case - side opening 31c.

[0032] In this way, the first, second, and third motor - case - side abutting surfaces MF1, MF2, MF3 and the motor - case - side abutting portion 35 are arranged around the rotation axis 39 with the motor - case - side opening 31c as the center.

[0033] The first, second, and third motor case side segments ML1, ML2, and ML3 each form an isosceles triangle, and the relationship of the length dimensions L1, L2, and L3 of the first, second, and third motor case side segments ML1, ML2, and ML3 is L3 > L1 > L2.

[0034] Further, a pressing portion 36 for pressing the ground terminal 70 (see FIG. 9) toward the gear case 51 is provided between the second motor case side corner portion 33 and the third motor case side corner portion 34 of the flange portion 31d. That is, the ground terminal 70 is among the first, second, and third motor case side segments ML1, ML2, and ML3 connecting the first, second, and third motor case side abutting surfaces MF1, MF2, and MF3 adjacent to each other in the circumferential direction of the rotating shaft 39, and is disposed only between the second motor case side abutting surface MF2 and the third motor case side abutting surface MF3 that form the shortest second motor case side segment ML2.

[0035] The ground terminal 70 is in the shape of a bar extending in the axial direction of the rotating shaft 39 and is disposed only between the second motor case side abutting surface MF2 and the third motor case side abutting surface MF3.

[0036] As a result, the pressing portion 36 is disposed only on the shortest second motor case side segment ML2 when the sunroof motor 20 is viewed from the axial direction of the rotating shaft 39. Therefore, the pressing portion 36 does not deform when the motor case 31 is fixed to the gear case 51 using the fixing screw FS, and the ground terminal 70 can be reliably pressed. Thus, the ground terminal 70 is disposed between the second motor case side abutting surface MF2 and the third motor case side abutting surface MF3 and overlaps with the pressing portion 36 when the sunroof motor 20 is viewed from the axial direction of the rotating shaft 39.

[0037] The ground terminal 70 is electrically connected to the motor case 31 by being pressed by the pressing portion 36. Also, the first, second, and third motor case side segments ML1, ML2, and ML3 respectively correspond to the line segments in the present invention.

[0038] [Stator] As shown in FIG. 4, a stator 37 is accommodated inside a side wall portion 31a that forms a motor case 31. The stator 37 has a stator core 37a formed by laminating a plurality of thin steel plates. The stator core 37a is fixed to the inner side of the side wall portion 31a and includes a total of six teeth 37b (not shown in detail). Three-phase coils CL consisting of a U-phase, a V-phase, and a W-phase are respectively wound around these teeth 37b via an insulator 37c.

[0039] [Rotor] As shown in FIG. 4, a rotor 38 is rotatably provided via an air gap AG inside the radial direction of the stator 37. The rotor 38 has a rotor core 38a formed in a substantially cylindrical shape. The rotor core 38a is formed by laminating a plurality of thin steel plates, and a total of four magnets MG are attached to the outer peripheral portion of the rotor core 38a. Specifically, each magnet MG is arranged at equal intervals (90-degree intervals) in the circumferential direction of the rotor core 38a.

[0040] In addition, the outer peripheral portion of each magnet MG attached to the rotor core 38a is covered with a magnet holder 38b formed in a substantially cylindrical shape by a thin stainless steel plate or the like. The magnet holder 38b has a function of fixing the magnet MG to the rotor core 38a. Thereby, even when the rotor 38 rotates at high speed, the magnet MG does not fall off from the rotor core 38a due to the centrifugal force at that time.

[0041] [Rotating shaft] A rotating shaft 39 is fixed by press-fitting to the center of rotation of the rotor core 38a. That is, the sunroof motor 20 includes the rotating shaft 39. The rotating shaft 39 is made of a round steel bar to ensure sufficient strength.

[0042] On the other hand, the proximal end side in the axial direction of the rotating shaft 39 (the right side in FIG. 4) is housed inside the motor case 31 and is rotatably supported by a first radial bearing B1 provided on the bottom wall portion 31b of the motor case 31. On the other hand, the distal end side in the axial direction of the rotating shaft 39 (the left side in FIG. 4) is housed inside the gear case 51 forming the speed reduction mechanism portion 50 and is rotatably supported by a second radial bearing B2 provided in the worm housing portion 59 of the gear case 51.

[0043] As described above, in this embodiment, the rotating shaft 39 is rotatably housed in both the motor case 31 and the gear case 51. Therefore, in order to rotate the rotating shaft 39 smoothly, it is important to accurately arrange the motor case 31 and the gear case 51 coaxially with each other.

[0044] Also, on the distal end side in the axial direction of the rotating shaft 39, a worm 40 forming a speed reduction mechanism SD is integrally provided by forging or the like. That is, the worm 40 is also made of a round steel bar. As a result, the rigidity of the worm 40 is increased and the worm 40 does not bend. Therefore, the worm 40 is surely meshed with the worm wheel 56.

[0045] [Ball bearing] A ball bearing 41 is mounted on the central portion in the axial direction of the rotating shaft 39. That is, the ball bearing 41 is provided between the first radial bearing B1 and the second radial bearing B2 in the axial direction of the rotating shaft 39 and rotatably supports the central portion in the axial direction of the rotating shaft 39. Specifically, a rotor core 38a to which a magnet MG is fixed is disposed between the ball bearing 41 and the first radial bearing B1, and a worm 40 is disposed between the ball bearing 41 and the second radial bearing B2.

[0046] The ball bearing 41, like the first radial bearing B1 and the second radial bearing B2, rotatably supports the rotating shaft 39 and includes an inner race 41a and an outer race 41b. Also, a plurality of balls 41c are provided between the inner race 41a and the outer race 41b.

[0047] And the inner race 41a is fixed to the rotating shaft 39 by press-fitting. That is, the inner race 41a rotates together with the rotating shaft 39.

[0048] [Sensor Magnet Unit] In the axial direction of the rotating shaft 39, a sensor magnet unit 42 is provided between the worm 40 and the ball bearing 41. The sensor magnet unit 42 has a cylindrical bracket member 42a fixed to the rotating shaft 39 by press-fitting and a sensor magnet 42b held by the bracket member 42a. Here, the sensor magnet 42b is used to detect the rotation state of the rotating shaft 39 (rotor 38), specifically, the rotation direction, rotation speed, etc.

[0049] Note that in the sensor magnet unit 42 as well, like the inner race 41a of the ball bearing 41, it rotates together with the rotating shaft 39.

[0050] [Holder Member] Also, the electric motor unit 30 has a holder member 43. The holder member 43 is made of a resin material such as plastic and includes a support body 43a formed in a substantially flat plate shape and a wall portion 43b that enters the gear case 51. That is, the holder member 43 is a component that is attached to the gear case 51.

[0051] An annular support portion 43c is integrally provided on a support main body 43a of a holder member 43. The annular support portion 43c supports an outer race 41b of a ball bearing 41 from one axial side (the right side in FIG. 4). Note that the other axial side (the left side in FIG. 4) of the outer race 41b is supported by a bearing mounting portion 60 provided in a gear case 51.

[0052] In this way, the outer race 41b of the ball bearing 41 is sandwiched between the gear case 51 and the holder member 43 in the axial direction of the rotation shaft 39. The holder member 43 is fixed to the gear case 51 by a total of three fixing screws FS, and thus is fixed inside the gear case 51 without rattling.

[0053] Three conductors 44 (see FIG. 3) are mounted on the support main body 43a corresponding to the three-phase coils CL. The conductors 44 are formed in a substantially rod shape from brass or the like having excellent conductivity and extend in the axial direction of the rotor 38. One longitudinal side (the right side in FIG. 4) of the conductor 44 is electrically connected to the three-phase coils CL, and the other longitudinal side (the left side in FIG. 4) of the conductor 44 is supported by a conductor support portion 59a of the gear case 51.

[0054] A motor substrate MB is electrically connected to the other longitudinal side of the conductor 44 (not shown in detail), and a connection terminal of an external connector (not shown in the figure) provided on the vehicle 12 (see FIG. 1) side is electrically connected to the motor substrate MB. Therefore, drive current is supplied from an in-vehicle controller or the like to the three-phase coils CL of the sunroof motor 20, and the rotation shaft 39 is rotated in the forward and reverse directions.

[0055] Here, the motor substrate MB is actually mounted on the side where the cover member 58 of the gear case 51 is provided (see FIG. 3). That is, the motor substrate MB is provided so as to overlap the cover member 58 in the axial direction of the output shaft 57 (see FIG. 2). Note that the cover member 58 is electrically connected to both the motor substrate MB and the ground terminal 70. Further, as indicated by the reference symbol G in FIGS. 3 and 4, the motor substrate MB is connected (grounded) to the body of the vehicle 12 serving as the reference potential.

[0056] As a result, the electrical noise generated during the rotation of the rotary shaft 39 flows from the motor case 31 to the ground terminal 70 and is discharged to the body of the vehicle 12 through the cover member 58 and the motor substrate MB. Therefore, the radiation of electrical noise around the sunroof motor 20 is suppressed, and thus it is possible to avoid adversely affecting other in-vehicle devices (such as a car audio).

[0057] [Gear case] As shown in FIGS. 2 to 4 and FIGS. 6 to 8, the speed reduction mechanism portion 50 includes a gear case 51 that houses the speed reduction mechanism SD. The gear case 51 is formed of a resin material such as plastic into a flat substantially rectangular parallelepiped shape and abuts against the motor case 31 in the axial direction of the rotary shaft 39. Specifically, the resin gear case 51 has a first wall portion 52, a second wall portion 53, and a third wall portion 54.

[0058] As shown in FIG. 4, a worm wheel housing portion 55 is provided inside the gear case 51. The worm wheel housing portion 55 is aligned with the third wall portion 54 in the axial direction of the rotary shaft 39. And inside the worm wheel housing portion 55, a worm wheel 56 forming the speed reduction mechanism SD is rotatably housed. Here, the worm wheel 56 is provided with a tooth portion 56a, and the tooth portion 56a meshes with the worm 40 inside the gear case 51.

[0059] In this way, the speed reduction mechanism SD is a worm speed reducer that can obtain a relatively large speed reduction ratio. In this embodiment, the speed reduction ratio of the speed reduction mechanism SD is "1 / 67". That is, when the worm 40 rotates 67 times, the worm wheel 56 rotates only once. Of course, it can also be set to other speed reduction ratios.

[0060] Also, at the rotation center of the worm wheel 56, the base end side in the axial direction of the output shaft 57 made of a round steel bar is fixed. On the other hand, on the tip end side in the axial direction of the output shaft 57, an output gear 57a (see FIG. 2) meshed with a pair of drive cables 17a, 17b (see FIG. 1) is integrally provided.

[0061] As a result, the high-speed rotation of the rotating shaft 39 is reduced by the speed reduction mechanism SD, and the rotational force that has been reduced and increased in torque is transmitted to the pair of drive cables 17a, 17b via the output shaft 57 and the output gear 57a. Here, the speed reduction mechanism SD is formed by the worm 40 and the worm wheel 56.

[0062] The worm 40 and the worm wheel 56 are rotatably accommodated inside the gear case 51 and are rotated by the rotating shaft 39, and each corresponds to the gear in the present invention.

[0063] Here, the worm wheel accommodating portion 55 is open on the side opposite to the side where the first wall portion 52 is provided in the axial direction of the output shaft 57 (the front side in FIG. 4). And the opening portion of the worm wheel accommodating portion 55 is closed by a cover member 58 formed in a substantially disc shape by pressing a steel plate or the like as shown in FIG. 3. That is, the cover member 58 closes the first opening OP1 (see FIGS. 6 and 10) provided in the gear case 51.

[0064] The first opening OP1 corresponds to the opening in the present invention.

[0065] Also, as shown in FIG. 4, a worm housing portion 59 is provided inside the gear case 51. The worm housing portion 59 is disposed near the second wall portion 53. And the worm housing portion 59 is arranged side by side with the worm wheel housing portion 55 in a direction orthogonal to the axial direction of the rotary shaft 39, and the inside of the worm housing portion 59 and the inside of the worm wheel housing portion 55 communicate with each other. Thereby, the worm 40 and the tooth portion 56a can mesh with each other.

[0066] The worm housing portion 59 extends in the axial direction of the rotary shaft 39, and a second radial bearing B2 that rotatably supports the tip side in the axial direction of the rotary shaft 39 is housed on the other axial side (the left side in FIG. 4) of the worm housing portion 59.

[0067] Furthermore, a conductor support portion 59a is provided between the worm housing portion 59 and the second wall portion 53. The conductor support portion 59a supports the other longitudinal side (the left side in FIG. 4) of the three conductors 44 held by the holder member 43 so as not to rattle. Thereby, the motor substrate MB can be easily connected to each conductor 44.

[0068] Also, a bearing mounting portion 60 is provided inside the gear case 51. The bearing mounting portion 60 is disposed on one axial side (the right side in FIG. 4) of the worm housing portion 59 and opens toward the motor case 31. And a ball bearing 41 is housed inside the bearing mounting portion 60.

[0069] Thus, the rotary shaft 39 is supported at three points by the first radial bearing B1, the second radial bearing B2, and the ball bearing 41. Thereby, when the sunroof motor 20 operates, the worm 40 does not separate from the tooth portion 56a of the worm wheel 56 (the meshing between them does not come off), and power can be reliably transmitted between them.

[0070] Here, an inner race 41a is fixed to the rotating shaft 39, and the outer race 41b is clamped between the bearing mounting portion 60 and the holder member 43. Therefore, the rotating shaft 39 does not move in the axial direction. Thus, it is not necessary to provide thrust bearings on both axial sides of the rotating shaft 39, and the number of parts is reduced.

[0071] [Motor housing portion] As shown in FIGS. 4, 6 to 8, a motor housing portion 61 formed in a substantially box shape is integrally provided in the gear case 51. The motor housing portion 61 is disposed on the side where the motor case 31 is provided in the axial direction of the rotating shaft 39 (the right side in FIG. 4). And the motor housing portion 61 has a second opening OP2 on the side where the motor case 31 is provided, and a part of the electric motor portion 30 is housed in the motor housing portion 61. Specifically, as shown in FIG. 4, the wall portion 43b of the holder member 43 forming the electric motor portion 30 enters the motor housing portion 61.

[0072] Also, as shown in FIGS. 6 and 7, the motor housing portion 61 is formed in a substantially rectangular shape when viewed from the axial direction of the rotating shaft 39. And on the side of the motor housing portion 61 where the motor case 31 is provided and at the four corners, a first gear case side corner portion 62, a second gear case side corner portion 63, a third gear case side corner portion 64, and a gear case side abutting portion 65 are provided respectively.

[0073] The first gear case side corner portion 62 has a first gear case side abutting surface GF1 (see the shaded portion in FIGS. 6 and 7) on the side opposite to the worm housing portion 59 side in the axial direction of the motor housing portion 61 (the motor case 31 side). The first gear case side abutting surface GF1 is a portion that abuts against the first motor case side abutting surface MF1 (see FIG. 5) of the motor case 31 in the axial direction of the rotating shaft 39. And a first female screw portion 62a to which a fixing screw FS is screwed is provided in the first gear case side corner portion 62.

[0074] The second gear case side corner 63 has a second gear case side abutting surface GF2 (refer to the shaded portion in FIGS. 6 and 7) on the side opposite to the worm housing portion 59 side (motor case 31 side) in the axial direction of the motor housing portion 61. The second gear case side abutting surface GF2 is a portion that abuts against the second motor case side abutting surface MF2 (refer to FIG. 5) of the motor case 31 in the axial direction of the rotation shaft 39. And, a second female screw portion 63a to which the fixing screw FS is screwed is provided on the second gear case side corner 63.

[0075] The third gear case side corner 64 has a third gear case side abutting surface GF3 (refer to the shaded portion in FIGS. 6 and 7) on the side opposite to the worm housing portion 59 side (motor case 31 side) in the axial direction of the motor housing portion 61. The third gear case side abutting surface GF3 is a portion that abuts against the third motor case side abutting surface MF3 (refer to FIG. 5) of the motor case 31 in the axial direction of the rotation shaft 39. And, a third female screw portion 64a to which the fixing screw FS is screwed is provided on the third gear case side corner 64.

[0076] Note that the total of three first, second, and third gear case side abutting surfaces GF1, GF2, and GF3 provided in the motor housing portion 61 of the gear case 51 are provided between the motor case 31 and the gear case 51, and each corresponds to the abutting surface in the present invention.

[0077] Also, the gear case side abutting portion 65 is a portion that abuts against the motor case side abutting portion 35 (refer to FIG. 5) of the motor case 31 in the axial direction of the rotation shaft 39. And, the gear case side abutting portion 65 is disposed at a position facing the second gear case side corner 63 with the second opening OP2 as the center.

[0078] Here, the first, second, and third gear case side corners 62, 63, 64 and the gear case side abutting portion 65 are accurately arranged at the same positions with respect to the axial direction of the rotary shaft 39 by a mold (not shown) used when molding the gear case 51. Further, the first, second, and third gear case side corners 62, 63, 64 and the gear case side abutting portion 65 extend accurately without distortion in a direction orthogonal to the axial direction of the motor housing portion 61 (the left - right direction in FIG. 4). Therefore, the first, second, and third gear case side corners 62, 63, 64 and the gear case side abutting portion 65 can be abutted against the motor case 31 without rattling. Thus, the gear case 51 and the motor case 31 can be arranged coaxially and straightly with respect to each other.

[0079] Furthermore, the first, second, and third gear case side corners 62, 63, 64 and the gear case side abutting portion 65 protrude by a height dimension T1 (see FIG. 8) with respect to an edge portion E provided on the second opening OP2 side of the motor housing portion 61. Specifically, the first, second, and third gear case side corners 62, 63, 64 and the gear case side abutting portion 65 protrude by the height dimension T1 from the edge portion E to one side in the axial direction of the rotary shaft 39 (the upper side in FIG. 8).

[0080] Thereby, the area (contact area) of the abutting portion (see the shaded portion in FIGS. 5 to 7) between the gear case 51 and the motor case 31 is reduced, and the gear case 51 and the motor case 31 can be easily butted against each other without rattling. Thus, the gear case 51 and the motor case 31 can be accurately arranged coaxially and straightly.

[0081] Here, the first gear case side abutting surface GF1 and the first motor case side abutting surface MF1 are abutted against each other to form a pair, forming the first fixing portion FP1. Also, the second gear case side abutting surface GF2 and the second motor case side abutting surface MF2 are abutted against each other to form a pair, forming the second fixing portion FP2. Further, the third gear case side abutting surface GF3 and the third motor case side abutting surface MF3 are abutted against each other to form a pair, forming the third fixing portion FP3.

[0082] Note that the three first, second, and third fixing parts FP1, FP2, and FP3 respectively correspond to the fixing part in the present invention.

[0083] As shown in FIG. 7, a first gear case side abutting surface GF1 having a first female screw portion 62a disposed at the center and a second gear case side abutting surface GF2 having a second female screw portion 63a disposed at the center are connected by a first gear case side line segment GL1 that extends in the width direction of the sunroof motor 20 (the vertical direction in FIG. 4).

[0084] Also, a second gear case side line segment GL2 that connects the second gear case side abutting surface GF2 having the second female screw portion 63a disposed at the center and the third gear case side abutting surface GF3 having the third female screw portion 64a disposed at the center extends in the thickness direction of the sunroof motor 20 (the depth direction in FIG. 4).

[0085] Furthermore, a third gear case side line segment GL3 that connects the first gear case side abutting surface GF1 having the first female screw portion 62a disposed at the center and the third gear case side abutting surface GF3 having the third female screw portion 64a disposed at the center extends so as to cross the substantially axial center portion of the motor housing portion 61, that is, the substantially central portion of the second opening OP2.

[0086] In this way, the first, second, and third gear case side abutting surfaces GF1, GF2, and GF3 and the gear case side abutting portion 65 are arranged around the rotation axis 39 with the second opening OP2 as the center.

[0087] The first, second, and third gear case side line segments GL1, GL2, and GL3 respectively form isosceles triangles, and the magnitude relationship of the length dimensions L1, L2, and L3 of the first, second, and third gear case side line segments GL1, GL2, and GL3 is L3 > L1 > L2.

[0088] And in the state where the sunroof motor 20 is assembled, a clamping portion 73 (see FIG. 9) of the ground terminal 70 is disposed between a second gear case side corner portion 63 and a third gear case side corner portion 64 of the motor housing portion 61. That is, the ground terminal 70 is disposed only between a second gear case side abutting surface GF2 and a third gear case side abutting surface GF3 that form a second gear case side line segment GL2, which is the shortest among first, second, and third gear case side line segments GL1, GL2, and GL3 connecting the first, second, and third gear case side abutting surfaces GF1, GF2, and GF3 adjacent to each other in the circumferential direction of the rotating shaft 39.

[0089] Note that the ground terminal 70 is in a rod shape extending in the axial direction of the rotating shaft 39 and is disposed only between the second gear case side abutting surface GF2 and the third gear case side abutting surface GF3. Also, the first, second, and third gear case side line segments GL1, GL2, and GL3 respectively correspond to the line segments in the present invention.

[0090] [Terminal mounting portion] As shown in FIGS. 6 to 8, a terminal mounting portion 66 is provided in the motor housing portion 61. Specifically, when the motor housing portion 61 is viewed from the axial direction of the rotating shaft 39, the terminal mounting portion 66 is disposed between the second gear case side corner portion 63 and the third gear case side corner portion 64. That is, the terminal mounting portion 66 is disposed on the second gear case side line segment GL2 when the motor housing portion 61 is viewed from the axial direction of the rotating shaft 39.

[0091] The terminal mounting portion 66 has a function of supporting the ground terminal 70. As shown in FIG. 6, the terminal mounting portion 66 includes a first terminal insertion hole 66a, a second terminal insertion hole 66b, and a terminal abutting portion 67. The cross sections of both the first and second terminal insertion holes 66a and 66b in a direction orthogonal to the axial direction of the rotating shaft 39 are substantially rectangular.

[0092] Also, as shown in FIG. 7, the first terminal insertion hole 66a is disposed on the side opposite to the second opening OP2 side of the motor housing portion 61 (the lower side in FIG. 7) when viewed from the axial direction of the rotation shaft 39. On the other hand, the second terminal insertion hole 66b is disposed on the second opening OP2 side of the motor housing portion 61 (the upper side in FIG. 7) when viewed from the axial direction of the rotation shaft 39. Thus, the first and second terminal insertion holes 66a and 66b are disposed at different positions in the direction orthogonal to the axial direction of the rotation shaft 39, respectively.

[0093] Furthermore, as shown in FIG. 6, in the axial direction of the rotation shaft 39, the first terminal insertion hole 66a is disposed on the second opening OP2 side of the motor housing portion 61, and the second terminal insertion hole 66b is disposed on the bearing mounting portion 60 side of the motor housing portion 61. Thus, the first and second terminal insertion holes 66a and 66b are disposed at different positions in the axial direction of the rotation shaft 39, respectively. That is, the first terminal insertion hole 66a is disposed on the outer side of the gear case 51 in the axial direction of the rotation shaft 39, and the second terminal insertion hole 66b is disposed on the inner side of the gear case 51 in the axial direction of the rotation shaft 39.

[0094] Thereby, the short portion 71 (see FIG. 9) of the ground terminal 70 can be inserted into the first terminal insertion hole 66a, and the long portion 72 (see FIG. 9) of the ground terminal 70 can be inserted into the second terminal insertion hole 66b.

[0095] Also, as shown in FIGS. 6 and 7, the terminal abutting portion 67 is disposed between the first terminal insertion hole 66a and the second terminal insertion hole 66b in the direction orthogonal to the axial direction of the rotation shaft 39. And, as shown in FIGS. 6 and 8, the terminal abutting portion 67 includes a pair of insertion guides 67a and a pair of triangular convex portions 67b.

[0096] The pair of insertion guides 67a has a function of guiding the attachment of the ground terminal 70 to the terminal attachment portion 66, that is, guiding the insertion operation of the ground terminal 70 into the first and second terminal insertion holes 66a and 66b. On the other hand, as shown in FIG. 8, the tip side (the upper side in FIG. 8) of the pair of triangular convex portions 67b has a tapered shape, and when the gear case 51 and the motor case 31 are butted against each other and fixed to each other, it becomes a portion to be crushed by the clamping portion 73 (see FIG. 9) of the ground terminal 70.

[0097] Note that since the pair of triangular convex portions 67b is made of resin, it has some elasticity. Therefore, the pair of triangular convex portions 67b has a function of pushing back the clamping portion 73 of the ground terminal 70 toward the motor case 31.

[0098] Here, the pair of triangular convex portions 67b provided on the gear case 51 corresponds to the convex portions in the present invention.

[0099] As shown in FIG. 8, in the axial direction of the rotating shaft 39 (the vertical direction in FIG. 8), with the position of the edge E of the motor housing portion 61 as a reference, the height dimensions of the first, second, and third gear case side corner portions 62, 63, 64 and the gear case side abutting portion 65 are T1, the depth dimension to the top of the insertion guide 67a is D1, the depth dimension to the top of the triangular convex portion 67b is D2, and the thickness dimension of the ground terminal 70 (clamping portion 73) is T2, then the following formula (1) holds. (D2 + T1) < T2 < (D1 + T1) … Formula (1)

[0100] That is, when the lower surface BS of the clamping portion 73 is placed on the pair of triangular convex portions 67b and the pair of triangular convex portions 67b are not crushed respectively, the upper surface US1 of the clamping portion 73 protrudes on one side in the axial direction of the rotating shaft 39 (the upper side in FIG. 8) from the first, second, and third gear case side abutting surfaces GF1, GF2, GF3 and the upper surface US2 of the gear case side abutting portion 65. The state where such an upper surface US1 protrudes on one side in the axial direction of the rotating shaft 39 from the first, second, and third gear case side abutting surfaces GF1, GF2, GF3 and the upper surface US2 (see FIG. 7) is referred to as the "clamping portion placement state".

[0101] In the "clamping part placement state", when the motor case 31 is abutted against the gear case 51 and a total of three fixing screws FS (see Fig. 10) are tightened with a specified tightening torque, the clamping part 73 is pressed by the pressing part 36 (see Fig. 5) of the motor case 31. As a result, the tip sides of the pair of triangular convex parts 67b are crushed toward the other side in the axial direction of the rotation shaft 39 (the lower side in Fig. 8). Therefore, the upper surface US1 of the clamping part 73, and the first, second, and third gear case side abutting surfaces GF1, GF2, GF3 and the upper surface US2 (see Fig. 7) are in a "flush state", respectively.

[0102] Here, in the "flush state", the lower surface BS of the clamping part 73 and the tops of the pair of insertion guides 67a are in a non-contact state with each other. That is, when the crushing allowance of the pair of triangular convex parts 67b is Δt, the following formula (2) is satisfied. Δt=(D1+T1)-T2…Formula (2)

[0103] And since the thickness dimension T2 of the clamping part 73 is smaller than the value obtained by adding the depth dimension D1 to the top of the insertion guide 67a and the height dimensions T1 of the first, second, and third gear case side corners 62, 63, 64 and the gear case side abutting part 65 (see the above formula (1)), the clamping part 73 only needs to crush a part of the tip side of the pair of triangular convex parts 67b.

[0104] As a result, the ground terminal 70 is fixed to the terminal mounting part 66 so as not to rattle at a specified position. Also, it is possible to prevent the tightening torque of the total of three fixing screws FS from becoming excessive, and damage to the first, second, and third female screw parts 62a, 63a, 64a (made of resin) is suppressed. Further, the clamping part 73 of the ground terminal 70 is pushed back toward the pressing part 36 by the pair of triangular convex parts 67b and is surely electrically connected to the motor case 31.

[0105] [Ground Terminal] The ground terminal 70 mounted on the terminal mounting part 66 is formed in a substantially J shape by punching out a brass plate or the like having excellent conductivity into a rod shape and bending it, as shown in Fig. 9. Specifically, the ground terminal 70 includes a short part 71, a long part 72, and a clamping part 73.

[0106] The width dimension of the short portion 71 is smaller than the width dimension of the long portion 72, and the length dimension of the short portion 71 is approximately 1 / 5 of the length dimension of the long portion 72. Further, the clamping portion 73 is a portion that is clamped between the motor case 31 and the gear case 51, and includes a lower surface BS and an upper surface US1.

[0107] Thus, by forming the ground terminal 70 in a substantially J shape, the short portion 71 can be inserted into the first terminal insertion hole 66a, and the long portion 72 can be inserted into the second terminal insertion hole 66b.

[0108] The short portion 71 includes a short main body 71a, and the clamping portion 73 is integrally provided at the base end portion of the short main body 71a. The short main body 71a and the clamping portion 73 are bent so as to be perpendicular (90 degrees) to each other.

[0109] Further, at the tip end portion of the short main body 71a, a short-side tapered portion 71b that gradually tapers toward the tip end side is provided. Here, the short-side tapered portion 71b has a function of guiding the insertion operation of the short portion 71 into the first terminal insertion hole 66a.

[0110] Furthermore, hook claws 71c are respectively provided on both sides in the width direction of the short main body 71a. Here, the pair of hook claws 71c are portions that are hooked inside the first terminal insertion hole 66a when the short portion 71 is inserted into the first terminal insertion hole 66a. Thereby, the ground terminal 70 can be temporarily fixed to the terminal mounting portion 66. That is, when the motor case 31 is fixed to the gear case 51, the ground terminal 70 is prevented from falling off from the terminal mounting portion 66.

[0111] Note that the pair of hook claws 71c that are hooked on the gear case 51 correspond to the claw portions in the present invention.

[0112] The long portion 72 includes a long main body 72a, and a clamping portion 73 is integrally provided at the base end portion of the long main body 72a. The long main body 72a and the clamping portion 73 are bent so as to be perpendicular (90 degrees) to each other. As a result, the short portion 71 and the long portion 72 are parallel to each other with the clamping portion 73 therebetween.

[0113] In addition, at the tip of the long main body 72a, a long-side tapered portion 72b having a gradually tapered shape toward the tip side is provided. Here, the long-side tapered portion 72b has a function of guiding the insertion operation into the second terminal insertion hole 66b of the long portion 72. Note that the tip side of the long portion 72 is electrically connected to the fixed leg portion 58b (see FIGS. 4 and 10) of the cover member 58.

[0114] The long portion 72 extends straight in the axial direction of the rotation shaft 39, and the tip side thereof is disposed inside the gear case 51, corresponding to the main body portion in the present invention.

[0115] The clamping portion 73 extends in a direction intersecting the axial direction of the rotation shaft 39, specifically, in a direction perpendicular to the axial direction of the rotation shaft 39. As shown in FIG. 8, the lower surface BS of the clamping portion 73 abuts against the terminal abutting portion 67 from one side in the axial direction of the rotation shaft 39 (the upper side in FIG. 8). On the other hand, the upper surface US1 of the clamping portion 73 is pressed by the pressing portion 36 (see FIG. 5) from one side in the axial direction of the rotation shaft 39 and is electrically connected to the motor case 31.

[0116] In this way, the metal ground terminal 70 has a function of electrically connecting the metal motor case 31 and the metal cover member 58 to each other in a state where the sunroof motor 20 is assembled. That is, electrical noise generated during the rotation of the rotation shaft 39 flows through the ground terminal 70.

[0117] The ground terminal 70 corresponds to the conductive member in the present invention.

[0118] [Cover member] As shown in FIG. 3, the cover member 58 includes a cover body 58a formed in a substantially disk shape. The cover body 58a closes the opening portion of the worm wheel accommodating portion 55 (the first opening OP1 of the gear case 51). Further, a total of four fixing legs 58b are integrally provided on the outer peripheral portion of the cover body 58a. These fixing legs 58b extend in the axial direction of the output shaft 57 (see FIG. 2) with respect to the cover body 58a. That is, the total of four fixing legs 58b are each bent with respect to the cover body 58a so as to be at a right angle (90 degrees).

[0119] And, as shown in FIG. 10, a pair of cover claws 58c are provided on the tip side of the fixing leg 58b, and these cover claws 58c are inserted into a total of four cover fixing holes 51a (see FIG. 4) provided in the gear case 51, and are in a state of being prevented from coming off with respect to the cover fixing holes 51a. And, as shown in FIG. 4, the tip side of the long portion 72 forming the ground terminal 70 is electrically connected to one of the total of four fixing legs 58b, specifically, the fixing leg 58b arranged in the upper right of FIG. 4.

[0120] In this way, the cover member 58 is electrically connected to both the motor substrate MB and the ground terminal 70, whereby the electrical noise generated during the rotation of the rotating shaft 39 is discharged from the motor case 31 to the body of the vehicle 12 (see FIG. 1) via the ground terminal 70, the cover member 58, and the motor substrate MB.

[0121] Note that the cover member 58 corresponds to the gear cover in the present invention.

[0122] [Metal jacket] Here, in the sunroof motor 20 of the present embodiment, in order to prevent electrical noise from being radiated to the outside, other electrical noise countermeasures are also taken.

[0123] Specifically, as shown in FIGS. 2 to 4, a metal jacket 80 formed by bending a thin steel plate is partially attached to the outside of the gear case 51. The metal jacket 80 partially covers the periphery of the rotating shaft 39 and the conductor 44 where electrical noise is likely to be transmitted. Thereby, the emission of electrical noise from the rotating shaft 39 and the conductor 44 to the outside of the sunroof motor 20 is suppressed.

[0124] [Assembly Procedure of Sunroof Motor] Next, the assembly procedure of the sunroof motor 20 formed as described above, particularly the assembly procedure of the ground terminal 70, the motor case 31, and the cover member 58 to the gear case 51, will be described in detail with reference to the drawings.

[0125] FIG. 10 shows an exploded perspective view of the sunroof motor (internal structure omitted), FIG. 11 shows a diagram for explaining the assembly procedure (1) of the sunroof motor, FIG. 12 shows a diagram for explaining the assembly procedure (2) of the sunroof motor, and FIG. 13 shows a diagram for explaining the assembly procedure (3) of the sunroof motor.

[0126] First, as shown in FIG. 10, prepare the gear case 51, the ground terminal 70, the motor case 31, the cover member 58, and a total of three fixing screws FS, each of which is manufactured through a different manufacturing process. In FIGS. 10 to 13, the illustration of the stator 37, the rotor 38, the holder member 43, etc. accommodated inside the motor case 31 and the worm wheel 56, etc. accommodated inside the gear case 51 is omitted.

[0127] As shown by the arrow M1 in FIGS. 10 and 11, the ground terminal 70 is made to face the terminal mounting portion 66 of the gear case 51 from one axial side (the right side in the figure) of the rotating shaft 39. Specifically, the tip side of the short portion 71 is made to face the first terminal insertion hole 66a, and the tip side of the long portion 72 is made to face the second terminal insertion hole 66b.

[0128] Next, insert the tip of the short portion 71 into the first terminal insertion hole 66a, and insert the tip of the long portion 72 into the second terminal insertion hole 66b. At this time, the ground terminal 70 is guided to the specified position of the terminal mounting portion 66 by a pair of insertion guides 67a. Further, the short portion 71 and the long portion 72 are guided in the insertion operation with respect to the first terminal insertion hole 66a and the second terminal insertion hole 66b by the short-side tapered portion 71b and the long-side tapered portion 72b. Therefore, the ground terminal 70 can be easily mounted on the terminal mounting portion 66.

[0129] As a result, as shown in FIG. 12, the lower surface BS of the clamping portion 73 is supported by the tips of the pair of triangular convex portions 67b. At this time, the upper surface US1 of the clamping portion 73 protrudes to one side in the axial direction of the rotation shaft 39 (right side in the figure) from the upper surfaces US2 of the first, second, and third gear case side abutting surfaces GF1, GF2, GF3 and the gear case side abutting portion 65 (see FIGS. 6 and 7), that is, in a "clamping portion placement state". As a result, the temporary fixing of the ground terminal 70 to the terminal mounting portion 66 is completed.

[0130] Note that in the "clamping portion placement state", the hook claw 71c (see FIG. 9) of the short portion 71 is hooked inside the first terminal insertion hole 66a. Therefore, the ground terminal 70 does not fall off from the gear case 51, and the assemblability is improved.

[0131] Next, as shown by the arrow M2 in FIGS. 10 and 13, bring the motor case 31 close to the motor housing portion 61 of the gear case 51 from one side in the axial direction of the rotation shaft 39 (right side in the figure). Specifically, in the axial direction of the rotation shaft 39, the first motor case side abutting surface MF1 (see FIG. 5) is opposed to the first gear case side abutting surface GF1 (see FIGS. 6 and 7), the second motor case side abutting surface MF2 (see FIG. 5) is opposed to the second gear case side abutting surface GF2 (see FIGS. 6 and 7), the third motor case side abutting surface MF3 (see FIG. 5) is opposed to the third gear case side abutting surface GF3 (see FIGS. 6 and 7), and the motor case side abutting portion 35 (see FIG. 5) is opposed to the gear case side abutting portion 65 (see FIGS. 6 and 7).

[0132] As a result, in the axial direction of the rotation shaft 39, the pressing portion 36 of the flange portion 31d faces the clamping portion 73 of the ground terminal 70.

[0133] Thereafter, as shown by the arrow M3 in FIG. 10, while inserting a total of three fixing screws FS into the first, second, and third screw insertion holes 32a, 33a, 34a, they are screwed to the first, second, and third female screw portions 62a, 63a, 64a with a specified tightening torque. As a result, the paired first motor case side abutting surfaces MF1 and the first gear case side abutting surfaces GF1 are abutted against each other, the paired second motor case side abutting surfaces MF2 and the second gear case side abutting surfaces GF2 are abutted against each other, the paired third motor case side abutting surfaces MF3 and the third gear case side abutting surfaces GF3 are abutted against each other, and the motor case side abutting portion 35 and the gear case side abutting portion 65 are abutted against each other.

[0134] Therefore, the motor case 31 is not rattling with respect to the gear case 51 and is arranged straight and coaxially with each other. At this time, by tightening each fixing screw FS with a specified tightening torque, as shown in FIG. 13, the upper surface US1 of the clamping portion 73 is pressed by the pressing portion 36 with a pressing force F from one side (the right side in the figure) in the axial direction of the rotation shaft 39. Therefore, the tip side of the pair of triangular convex portions 67b is crushed by the lower surface BS of the clamping portion 73 by the amount of the crushing allowance Δt (see FIG. 12). Thereby, the assembly work of the motor case 31 and the gear case 51 is completed.

[0135] Here, the specified tightening torque of the fixing screw FS that generates the pressing force F is a tightening torque of such a magnitude that the tip side of the pair of triangular convex portions 67b can be crushed by the amount of the crushing allowance Δt by the lower surface BS of the clamping portion 73 without damaging the resin-made first, second, and third female screw portions 62a, 63a, 64a.

[0136] Here, in the present embodiment, the motor case 31 and the gear case 51 are fixed to each other with a total of three fixing screws FS. This is because, for example, if the motor case 31 and the gear case 51 are fixed with a total of two fixing screws, the motor case 31 and the gear case 51 may incline with respect to each other around the line segment connecting the two fixing screws, and ultimately there is a risk of hindering the smooth rotation of the rotation shaft 39. On the other hand, for example, if the motor case 31 and the gear case 51 are fixed with a total of four fixing screws, in the relatively small sunroof motor 20, the fixing strength becomes excessive and the number of assembly steps increases.

[0137] Next, as shown by the arrow M4 in FIG. 10, the cover member 58 is made to face the opening side of the worm wheel housing portion 55, that is, the first opening OP1 of the gear case 51. At this time, the tip side of the fixing leg portion 58b is directed toward the cover fixing hole 51a of the gear case 51. Then, each fixing leg portion 58b is inserted into each cover fixing hole 51a. Thus, the cover claw 58c is in a state of being prevented from coming off with respect to the cover fixing hole 51a, and the attachment of the cover member 58 to the gear case 51 is completed.

[0138] As a result, as shown in FIG. 4, the tip side of the long portion 72 of the ground terminal 70 is electrically connected to the fixing leg portion 58b in the upper right of the drawing among the total of four fixing leg portions 58b.

[0139] As described in detail above, according to the present embodiment, a ground terminal 70 is provided which is sandwiched between the motor case 31 and the gear case 51 and through which electrical noise generated by the rotation of the rotation shaft 39 flows. Between the motor case 31 and the gear case 51, first to third fixing portions FP1 to FP3 are provided which are arranged around the rotation shaft 39 and consist of first to third motor case side abutting surfaces MF1 to MF3 and first to third gear case side abutting surfaces GF1 to GF3 that abut against each other.

[0140] The ground terminal 70 is disposed only between the second fixing portion FP2 and the third fixing portion FP3 that form the shortest line segment (the second motor case side line segment ML2 and the second gear case side line segment GL2) among the line segments (the first to third motor case side line segments ML1 to ML3 and the first to third gear case side line segments GL1 to GL3) connecting the first to third fixing portions FP1 to FP3 adjacent to each other in the circumferential direction of the rotation shaft 39.

[0141] Accordingly, when the motor case 31 is fixed to the gear case 51 using the fixing screws FS, the ground terminal 70 can be pressed against the terminal mounting portion 66 of the gear case 51 while directly abutting the motor case 31 and the gear case 51 coaxially with each other without deforming the flange portion 31d (pressing portion 36) of the motor case 31. Therefore, it is possible to improve the assemblability of the sunroof motor 20 and reduce the operating noise.

[0142] Further, according to the present embodiment, the ground terminal 70 includes an elongated portion 72 extending in the axial direction of the rotation shaft 39 and disposed inside the gear case 51, and a clamping portion 73 extending in a direction intersecting the axial direction of the rotation shaft 39 and clamped between the motor case 31 and the gear case 51.

[0143] Accordingly, electrical noise transmitted to the motor case 31 can be transmitted from the motor case 31 side in the axial direction of the rotation shaft 39 toward the gear case 51 side (the side where the motor substrate MB is provided) via the ground terminal 70.

[0144] Furthermore, according to the present embodiment, the elongated portion 72 is electrically connected to a metal cover member 58 that closes a first opening OP1 provided in the resin-made gear case 51.

[0145] Accordingly, electrical noise generated by the rotation of the rotation shaft 39 can be transmitted from the motor case 31 to the metal cover member 58 via the ground terminal 70.

[0146] Also, according to this embodiment, the gear case 51 has a pair of triangular convex portions 67b that are crushed by the clamping portion 73.

[0147] As a result, the clamping portion 73 of the ground terminal 70 is pushed back toward the pressing portion 36 of the motor case 31 by the pair of triangular convex portions 67b, and thus the ground terminal 70 can be surely electrically connected to the motor case 31.

[0148] Furthermore, according to this embodiment, the ground terminal 70 includes a pair of hook claws 71c that are hooked on the gear case 51.

[0149] As a result, the ground terminal 70 can be temporarily fixed to the terminal mounting portion 66. Therefore, when the motor case 31 and the gear case 51 are fixed to each other, it is possible to prevent the ground terminal 70 from falling off from the terminal mounting portion 66, and thus the assemblability of the sunroof motor 20 can be further improved.

[0150] Also, according to this embodiment, since the motor case 31 and the gear case 51 can be accurately assembled to each other, it is possible to save manufacturing energy by eliminating waste such as the occurrence of defective products and rework. As a result, among the Sustainable Development Goals (SDGs) defined by the United Nations, in particular, Goal 7 (ensuring access for all people to affordable, reliable, and sustainable modern energy) and Goal 13 (taking urgent measures to mitigate climate change and its impacts) can be achieved.

[0151] [Embodiment 2] Next, Embodiment 2 of the present invention will be described in detail with reference to the drawings. Note that parts having the same functions as those in Embodiment 1 are denoted by the same reference numerals, and detailed descriptions thereof are omitted.

[0152] FIG. 14 is a diagram corresponding to FIG. 11 showing Embodiment 2.

[0153] As shown in FIG. 14, in the sunroof motor 20 of the second embodiment, compared with the first embodiment (see FIG. 11), the shape of the terminal mounting portion 90 of the motor housing portion 61 and the shape of the ground terminal (conductive member) 100 mounted on the terminal mounting portion 90 are different.

[0154] Specifically, the terminal mounting portion 90 of the second embodiment has a second terminal insertion hole 66b while not having a first terminal insertion hole 66a, as compared with the terminal mounting portion 66 (see FIG. 11) of the first embodiment. Further, the terminal abutting portion 67 of the second embodiment is a simple flat surface extending in a direction orthogonal to the axial direction of the rotation shaft 39, and does not include a pair of insertion guides 67a and a pair of triangular convex portions 67b (see FIG. 11).

[0155] That is, the structure of the terminal mounting portion 90 of the second embodiment is simplified as compared with the terminal mounting portion 66 of the first embodiment.

[0156] Also, the ground terminal 100 of the second embodiment has a long portion 72 while not having a short portion 71, as compared with the ground terminal 70 (see FIG. 9) of the first embodiment. That is, the structure of the ground terminal 100 of the second embodiment is simplified as compared with the ground terminal 70 of the first embodiment.

[0157] Furthermore, the clamping portion 73 provided integrally at the base end portion of the long main body 72a is bent so as to be at an angle α (about 120 degrees) with respect to the long main body 72a. That is, the clamping portion 73 forming the ground terminal 100 of the second embodiment is inclined with respect to both the axial direction of the rotation shaft 39 and the direction orthogonal to the axial direction of the rotation shaft 39.

[0158] Thereby, by abutting the motor case 31 (see FIG. 5) against the gear case 51 and tightening the fixing screw FS (see FIG. 3) with a specified tightening torque, the clamping portion 73 is pressed by the pressing portion 36 (see FIG. 5) with a pressing force F. Therefore, the clamping portion 73 is elastically contacted so as to push back against the motor case 31 (pressing portion 36), and the ground terminal 100 and the motor case 31 are surely electrically contacted.

[0159] Here, as shown by the dashed circle in Fig. 14, with the ground terminal 100 mounted on the terminal mounting portion 90 and the motor case 31 not abutted against the gear case 51, the tip side (the lower right side in the figure) of the clamping portion 73 protrudes to one axial side (the right side in Fig. 14) of the rotary shaft 39 with respect to the first, second, and third gear case side abutting surfaces GF1, GF2, GF3 and the upper surface US2 (see Fig. 7) of the gear case side abutting portion 65.

[0160] Also in the second embodiment formed as described above, except for the temporary fixing function of the short portion 71 to the first terminal insertion hole 66a (see Fig. 12) in the first embodiment, substantially the same operational effects as those in the first embodiment can be achieved. In addition, in the second embodiment, since the structures of the terminal mounting portion 90 and the ground terminal 100 can be simplified, the manufacturing cost can be suppressed.

[0161] The present invention is not limited to the above-described embodiments, and it goes without saying that various modifications can be made without departing from the gist thereof. For example, in the above-described first embodiment, a pair of insertion guides 67a (see Fig. 6) are provided on the terminal abutting portion 67 of the terminal mounting portion 66, but the present invention is not limited thereto, and the pair of insertion guides 67a can also be omitted. Also, only one of the pair of triangular convex portions 67b may be provided, or the shape thereof may be a shape protruding in an arc shape upward. In short, as long as the strength of the convex portion is such that it can be crushed by the pressing force F (see Fig. 13), the number and shape of the convex portions are arbitrary.

[0162] Also, in the above-described embodiments, the present invention is shown as being applied to the sunroof motor 20 used in the sunroof device 10 of the vehicle 12, but the present invention is not limited thereto, and for example, it can also be applied to in-vehicle motor devices used in slide door devices, power window devices, wiper devices, etc. mounted on vehicles.

[0163] In addition, the materials, shapes, dimensions, numbers, installation locations, etc. of the respective components in each of the above embodiments are arbitrary as long as the present invention can be achieved, and are not limited to the above embodiments.

Explanation of Signs

[0164] 10: Sunroof device, 11: Roof panel, 12: Vehicle, 13: Roof, 14: Roof opening, 15a, 15b: Shoe, 16: Guide rail, 17a, 17b: Drive cable, 20: Sunroof motor (motor device), 30: Electric motor unit, 31: Motor case, 31a: Side wall part, 31b: Bottom wall part, 31c: Motor case side opening, 31d: Flange part, 32: First motor case side corner, 32a: First screw insertion hole, 33: Second motor case side corner, 33a: Second screw insertion hole, 34: Third motor case side corner, 34a: Third screw insertion hole, 35: Motor case side abutting part, 36: Pressing part, 37: Stator, 37a: Stator core, 37b: Teeth, 37c: Insulator, 38: Rotor, 38a: Rotor core, 38b: Magnet holder, 39: Rotation shaft, 40: Worm (gear), 41: Ball bearing, 41a: Inner race, 41b: Outer race, 41c: Ball, 42: Sensor magnet unit, 42a: Bracket member, 42b: Sensor magnet, 43: Holder member, 43a: Support body, 43b: Wall part, 43c: Annular support part, 44: Conductor, 50: Reduction mechanism part, 51: Gear case, 51a: Cover fixing hole, 52: First wall part, 53: Second wall part, 54: Third wall part, 55: Worm wheel housing part, 56: Worm wheel (gear), 56a: Tooth part, 57: Output shaft, 57a: Output gear, 58: Cover member (gear cover), 58a: Cover body, 58b: Fixed leg part, 58c: Cover claw, 59: Worm housing part, 59a: Conductor support part, 60: Bearing mounting part, 61: Motor housing part, 62: First gear case side corner, 62a: First female screw part, 63: Second gear case side corner, 63a: Second female screw part, 64: Third gear case side corner, 64a: Third female screw part, 65: Gear case side abutting part, 66: Terminal mounting part, 66a: First terminal insertion hole, 66b: Second terminal insertion hole, 67: Terminal abutting part, 67a: Insertion guide, 67b: Triangular convex part (convex part), 70: Ground terminal (conductive member), 71: Short part, 71a: Short body, 71b: Short side tapered part, 71c: Hooking claw (claw part), 72: Long part (main body part), 72a: Long body, 72b: Long side tapered part, 73: Clamping part, 80: Metal jacket, 90: Terminal mounting part, 100: Ground terminal (conductive member), AG: Air gap, B1: First radial bearing, B2: Second radial bearing,BS: Below, CL: Coil, E: Edge, FG: Front glass, FP1: First fixing part (fixing part), FP2: Second fixing part (fixing part), FP3: Third fixing part (fixing part), FS: Fixing screw, GF1: First gear case side abutting surface (abutting surface), GF2: Second gear case side abutting surface (abutting surface), GF3: Third gear case side abutting surface (abutting surface), GL1: First gear case side line segment (line segment), GL2: Second gear case side line segment (line segment), GL3: Third gear case side line segment (line segment), MB: Motor board, MF1: First motor case side abutting surface (abutting surface), MF2: Second motor case side abutting surface (abutting surface), MF3: Third motor case side abutting surface (abutting surface), MG: Magnet, ML1: First motor case side line segment (line segment), ML2: Second motor case side line segment (line segment), ML3: Third motor case side line segment (line segment), OP1: First opening (opening), OP2: Second opening, SD: Reduction mechanism, US1, US2: Upper surface, Δt: Crushing allowance,

Claims

1. A motor device comprising: a rotating shaft; a gear rotated by the rotating shaft; a motor case for housing the rotating shaft; a gear case for housing the gear; a conductive member sandwiched between the motor case and the gear case and through which electrical noise generated by the rotation of the rotating shaft flows; wherein at least three fixing portions each composed of a pair of abutting surfaces are provided between the motor case and the gear case, disposed around the rotating shaft and abutting against each other; the conductive member is disposed only between the fixing portions that form the shortest line segment among the line segments connecting the adjacent fixing portions in the circumferential direction of the rotating shaft; a motor device.

2. The motor device according to claim 1, wherein the conductive member includes a main body portion extending in the axial direction of the rotating shaft and disposed inside the gear case; a clamping portion extending in a direction intersecting the axial direction of the rotating shaft and clamped between the motor case and the gear case; and has a motor device.

3. The motor device according to claim 2, wherein the main body portion is electrically connected to a gear cover made of metal that closes an opening provided in the resin gear case.

4. The motor device according to claim 2, wherein the gear case has a convex portion that is crushed by the clamping portion.

5. The motor device according to claim 2, wherein the conductive member has a claw portion that is hooked on the gear case.

6. The motor device according to claim 2, wherein the clamping portion is inclined with respect to both the axial direction of the rotating shaft and a direction orthogonal to the axial direction of the rotating shaft.

7. The motor device according to claim 2, wherein the conductive member has a claw portion that is hooked on the gear case.

8. The motor device according to claim 2, wherein the clamping portion is inclined with respect to both the axial direction of the rotating shaft and a direction orthogonal to the axial direction of the rotating shaft.

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