Positioning component

Abstract

To reduce a gap between a terminal incorporated in a terminal block and a magnetic core.SOLUTION: A terminal block 30 includes a terminal 40, a magnetic core 32 that surrounds the terminal at a distance, and an insulating base body 50 that is filled between the terminal and the magnetic core and surrounds the magnetic core.SELECTED DRAWING: Figure 3

Description

[Technical Field]

[0001] The present disclosure relates to positioning components. [Background technology]

[0002] Patent document 1 discloses a terminal block having a base portion with a through hole formed therein, a conductive terminal inserted into the through hole, and a cover portion arranged to surround the conductive terminal and inserted into the through hole. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] Japanese Patent Publication No. 2022-161647 [Patent Document 2] Patent Publication No. 2021-125556 [Patent Document 3] Japanese Patent Publication No. 2020-205351 [Patent Document 4] Japanese Patent Publication No. 2022-21077 Summary of the Invention [Problem to be solved by the invention]

[0004] It is conceivable that the magnetic core is integrated with the terminal block, and in this case, it is desirable to reduce the gap between the terminal and the magnetic core.

[0005] Therefore, an object of the present disclosure is to reduce the gap between the terminal and the magnetic core. [Means for solving the problem]

[0006] The positioning component of the present disclosure is a positioning component that maintains a constant positional relationship between a terminal and a magnetic core that surrounds the terminal with a gap therebetween.

[0007] The positioning component includes an enclosing portion that encloses the terminal within the magnetic core, and a partial protrusion that partially protrudes from the outer circumferential surface of the enclosing portion and contacts the inner circumferential surface of the magnetic core. [Effects of the Invention]

[0008] According to the present disclosure, the gap between the terminal and the magnetic core can be reduced. [Brief explanation of the drawings]

[0009] [Figure 1] FIG. 1 is a schematic diagram showing an electromechanical integrated unit incorporating a terminal block according to an embodiment. [Figure 2] FIG. 2 is a perspective view showing the terminal block. [Figure 3] FIG. 3 is a cross-sectional view taken along line III-III in FIG. [Figure 4] FIG. 4 is a cross-sectional view taken along line IV-IV in FIG. [Figure 5] FIG. 5 is a perspective view showing the internal structure of the terminal block. [Figure 6] FIG. 6 is an exploded perspective view of the internal structure of the terminal block. [Figure 7] FIG. 7 is an explanatory diagram showing an example of an operation for inserting the first component into the magnetic core. [Figure 8] FIG. 8 is an explanatory diagram showing an example of a manufacturing process for a terminal block. DETAILED DESCRIPTION OF THE INVENTION

[0010] [Description of the embodiments of the present disclosure] First, embodiments of the present disclosure will be listed and described.

[0011] The terminal block of the present disclosure is as follows.

[0012] (1) A terminal block comprising a terminal, a magnetic core surrounding the terminal with a gap therebetween, and an insulating base body filled between the terminal and the magnetic core and surrounding the magnetic core.

[0013] According to the present disclosure, the base body is filled between the terminal and the magnetic core, which allows the terminal to be held in a fixed position relative to the magnetic core and also reduces the gap between the magnetic core and the terminal.

[0014] (2) In the terminal block of (1), the block body may include a first part and a second part, the first part maintains the terminal and the magnetic core in a fixed positional relationship, and the second part may cover the magnetic core while filling the gap between the terminal and the magnetic core.

[0015] In this case, the first part maintains a fixed positional relationship between the terminal and the magnetic core, so if the terminal is supported in a fixed position, the magnetic core will also be maintained in a fixed position. In this state, it can be easily molded to form the second part.

[0016] (3) In the terminal block of (2), the first component may have an enclosing portion that encloses the terminal within the magnetic core.

[0017] This makes it easier for the surrounding portion to insulate the magnetic core from the terminal.

[0018] (4) In the terminal block of (3), the first component may have a partial protrusion that partially protrudes from the outer circumferential surface of the surrounding portion and contacts the inner circumferential surface of the magnetic core.

[0019] By bringing the partial protrusion into contact with the inner circumferential surface of the magnetic core in this way, it is easy to form a gap between the surrounding portion and the magnetic core into which the resin can easily flow, and therefore it is difficult for a gap to remain between the surrounding portion and the magnetic core.

[0020] (5) In the terminal block of (4), the partial protrusion may be elongated along the longitudinal direction of the terminal.

[0021] This makes it easier to pour the resin between the surrounding portion and the magnetic core along the longitudinal direction of the terminal.

[0022] (6) In a terminal block according to any one of (3) to (5), the first part may have a long elastic portion that elastically deforms to move toward and away from the inner periphery of the magnetic core, and a locking protrusion that protrudes from the long elastic portion, and the locking protrusion may lock onto the magnetic core, thereby allowing the first part to maintain a constant positional relationship between the terminal and the magnetic core.

[0023] In this case, the locking projection can be locked to the magnetic core by elastically deforming the elongated elastic portion, which makes it difficult for a large force to be applied to the magnetic core during positioning, and the magnetic core is less likely to be distorted.

[0024] (7) In the terminal block of (6), the long elastic portion may extend at a distance from the outer circumferential surface of the surrounding portion.

[0025] In this case, the long elastic portion can be smoothly elastically deformed to reduce the gap between the long elastic portion and the outer peripheral surface of the surrounding portion, which makes it difficult for a large force to be applied to the magnetic core, and the magnetic core is less likely to be distorted.

[0026] (8) In the terminal block of any one of (3) to (7), the first component may have an end face positioning protrusion that protrudes from the outer peripheral surface of the enclosing portion and abuts against the end face of the magnetic core.

[0027] In this case, the end face positioning projections come into contact with the end faces of the magnetic core, making it easier to position the terminals at fixed positions relative to the magnetic core in the longitudinal direction.

[0028] (9) In the terminal block of any one of (1) to (8), the magnetic core may be a nanocrystalline magnetic core.

[0029] By using a nanocrystalline magnetic core as the magnetic core, the magnetic permeability can be increased, making it easier to miniaturize the terminal block. It is also suitable for use in high-temperature environments. Furthermore, by reducing the gap between the terminal and the nanocrystalline magnetic core, the nanocrystalline magnetic core is less likely to deform.

[0030] The method for manufacturing the terminal block of the present disclosure is as follows.

[0031] (10) A method for manufacturing a terminal block, in which the magnetic core is positioned relative to the terminal so that the magnetic core surrounds the terminal with a gap therebetween, and the terminal is set in a mold, thereby placing the magnetic core within the mold space of the mold, and injecting a fluid resin into the mold space to mold an insulating base body that fills the space between the terminal and the magnetic core and surrounds the magnetic core.

[0032] According to the present disclosure, the base body is filled between the terminal and the magnetic core, which allows the terminal to be held in a fixed position relative to the magnetic core and also reduces the gap between the magnetic core and the terminal.

[0033] [Details of the embodiments of the present disclosure] Specific examples of the terminal block and the method for manufacturing the terminal block according to the present disclosure will be described below with reference to the drawings. Note that the present disclosure is not limited to these examples, but is defined by the claims, and is intended to include all modifications within the meaning and scope of the claims.

[0034] [Embodiment] A terminal block and a method for manufacturing the terminal block according to an embodiment will be described below.

[0035] <Overall configuration of the electromechanical integrated unit with built-in terminal block> An example of the overall configuration of an electromechanical integrated unit with a terminal block built in will now be described.

[0036] The electromechanical integrated unit 10 includes a rotating electric machine 20 and an inverter 12 .

[0037] The rotating electric machine 20 is a rotating electric machine including a case 22, an armature 24, and a field 28. FIG. 1 shows an example in which the armature 24 is fixed as a stator inside the cylindrical case 22. The field 28 is disposed as a rotor inside the armature 24. The field 28 rotates due to a magnetic field generated by the armature 24, or the rotation of the field 28 causes the armature 24 to generate an electromotive force. In this embodiment, it is assumed that the rotating electric machine 20 is a rotating electric machine that can be used as a three-phase AC motor. The rotating electric machine may be capable of operating as a generator in addition to or instead of operating as a motor.

[0038] The armature 24 includes a stator core and a plurality of coil wires. The stator core includes a plurality of teeth that are arranged to surround the rotation axis. Each coil wire is wound around one or more teeth. At least some of the ends of the coil wires are drawn out from between the teeth to one axial end of the armature.

[0039] The armature 24 has coil connection ends 26. The coil connection ends 26 are, for example, elongated conductive plate-like portions. The coil connection ends 26 are arranged on one axial end side of the armature 24. Screw insertion holes for screw fastening are formed in the coil connection ends 26. The coil connection ends 26 may be the ends of the coil wires themselves, or may be metal plates connected to the coil wires by welding, screw fastening, or the like. In this embodiment, three coil connection ends 26 corresponding to the three phases are arranged in parallel at intervals on one end side of the armature 24.

[0040] The inverter 12 is a device having an inverter circuit. It is assumed that the inverter 12 is integrated with the rotating electric machine 20. For example, the inverter 12 is integrated with a case 22 of the rotating electric machine 20 by bolting or the like.

[0041] The inverter 12 includes bus bars 18 connected to the output terminals of the inverter circuit. The bus bars 18 are elongated plate-like members formed from a metal plate material such as copper or a copper alloy. Screw insertion holes for fastening the bus bars 18 are formed in the bus bars 18. In this embodiment, three bus bars 18 corresponding to the three phases extend from the inverter 12 toward the rotating electric machine 20 in a parallel state with a gap therebetween.

[0042] The terminal block 30 is a component that is fixed to the case 22 of the rotating electrical machine 20 and connects the rotating electrical machine 20 and the inverter 12. The terminal block 30 includes terminals 40 and a block body 50.

[0043] The base body 50 is fixed to the case 22 by screws or the like in a state where the mounting holes 22h formed in the case 22 are closed.

[0044] The terminal 40 penetrates the base body 50 and is held in a fixed position and posture relative to the base body 50 .

[0045] When the terminal 40 is fixed to the case 22, one end of the terminal 40 faces inside the case 22 and forms a first connection end 42 that is connected to an end of the coil connection end 26. When the terminal block 30 is fixed to the case 22, the first connection end 42 is positioned so as to overlap the coil connection end 26.

[0046] A first screw insertion hole 42h is formed in the first connection end 42. With the coil connection end 26 overlapping the first connection end 42, the first connection end 42 and the coil connection end 26 are fixed together with screws. This electrically connects the coil connection end 26 and the terminal 40.

[0047] When the terminals 40 are fixed to the case 22, the other ends of the terminals 40 face outward from the case 22 and are supported at positions connectable to the ends of the bus bars 18 of the inverter 12 as second connection ends 46. When the inverter 12 is integrated with the rotating electric machine 20, the second connection ends 46 are arranged at positions overlapping the bus bars 18. In this embodiment, three terminals 40 corresponding to the three phases are arranged in parallel with a gap between them.

[0048] A second screw insertion hole 46h is formed in the second connection end 46. With the bus bar 18 overlapped on the second connection end 46, the second connection end 46 and the bus bar 18 are fixed together with screws, thereby electrically connecting the bus bar 18 and the terminal 40.

[0049] The armature 24 in the rotating electric machine 20 is electrically connected to a circuit in the inverter 12 via a terminal 40 .

[0050] In this embodiment, the terminal block 30 includes three terminals 40. The terminal block 30 may include at least one terminal 40.

[0051] The connection between the terminal 40 and the coil connection end 26 or the bus bar 18 does not need to be made by screw fastening. For example, the terminal 40 and the coil connection end 26 or the bus bar 18 may be electrically connected by a fitting structure or a spring-biased structure.

[0052] The electromechanical integrated unit 10 is incorporated into, for example, a vehicle. The rotary driving force of the rotary electric machine 20 is used to run the vehicle, and the rotary electric machine 20 is rotated during vehicle braking to convert the inertial energy of the vehicle into electrical energy.

[0053] <About terminal blocks> The terminal block 30 will now be described. Fig. 2 is a perspective view showing the terminal block 30. Fig. 3 is a cross-sectional view taken along line III-III in Fig. 2. Fig. 4 is a cross-sectional view taken along line IV-IV in Fig. 3. Fig. 5 is a perspective view showing the internal structure of the terminal block 30. Fig. 6 is an exploded perspective view of the internal structure of the terminal block 30.

[0054] The terminal block 30 includes a terminal 40, a magnetic core 32, and a block body 50.

[0055] The terminal 40 is an elongated member made of a metal such as copper, a copper alloy, aluminum, or an aluminum alloy. In this embodiment, the terminal 40 is a long, thin metal plate. One end of the terminal 40 is the first connection end 42, and the other end is the second connection end 46. In this embodiment, the terminal 40 extends linearly. The terminal may be curved in its thickness direction or width direction.

[0056] In this embodiment, the terminal block 30 includes a plurality of (here, three) terminals 40. The plurality of terminals 40 are held by the block body 50 so as to be arranged in a row with spaces between them. The direction in which the plurality of terminals 40 are arranged may coincide with the width direction of the terminals 40.

[0057] The magnetic core 32 is a component formed in an annular shape from a magnetic material. The magnetic core 32 surrounds the terminals 40 with a gap therebetween. In this embodiment, one magnetic core 32 surrounds multiple terminals 40 with a gap therebetween. Therefore, the magnetic core 32 is formed in an annular shape that is long in the direction in which the multiple terminals 40 are arranged. A long, slender, oval cylindrical space is formed within the magnetic core 32 in which three terminals arranged in a straight line can be placed.

[0058] The outer peripheral surface of the magnetic core 32 may be formed by dividing the cylindrical outer peripheral surface into two parts, with the edges of the two parts joined by a flat surface. The inner peripheral surface of the magnetic core 32 may also be formed by dividing the cylindrical outer peripheral surface into two parts, with the edges of the two parts joined by a flat surface.

[0059] The magnetic material forming the magnetic core 32 is not particularly limited, and may be, for example, ferrite, an amorphous alloy, or a nanocrystalline alloy. Nanocrystalline alloys have higher magnetic permeability than ferrite. Therefore, if a nanocrystalline magnetic core formed from a nanocrystalline alloy is used as the magnetic core 32, the magnetic core 32 can be made smaller, and the terminal block 30 as a whole can be made smaller. In addition, nanocrystalline magnetic cores have the advantage of having good high-temperature properties and easily maintaining desired properties even in the high-temperature environments used in vehicle traction motors.

[0060] The base body 50 is an insulating portion that is filled between the terminal 40 and the magnetic core 32 and surrounds the magnetic core 32 .

[0061] The base body 50 is interposed between the terminal 40 and the magnetic core 32, thereby insulating the terminal 40 from the magnetic core 32. Furthermore, the base body 50 holds the terminal 40 in a fixed position and posture inside the magnetic core 32, thereby keeping the position of the terminal 40 relative to the magnetic core 32 and the base body 50 constant.

[0062] Furthermore, by filling the gap between the terminal 40 and the magnetic core 32 with the base body 50, the generation of a gap filled with gas between the terminal 40 and the magnetic core 32 is suppressed. By suppressing the generation of a gap between the terminal 40 and the magnetic core 32, the terminal 40 is less likely to vibrate within the terminal block 30. Furthermore, heat generated by the terminal block 30 and the magnetic core 32 is less likely to build up within the terminal block 30, and is dissipated efficiently.

[0063] The base body 50 is configured to hold the terminal 40 in a fixed position, to cover the magnetic core 32, and to be fixable to a rotating electrical machine 20, which is an example of equipment.

[0064] The specific shape of the base body 50 is not particularly limited, but in this embodiment, the base body 50 is formed to be larger than the magnetic core 32. For example, the height of the base body 50 is larger than the height of the magnetic core 32, and can cover both end faces of the magnetic core 32. Furthermore, the outer circumferential surface of the base body 50 is larger than the outer circumferential surface of the magnetic core 32, and can cover the entire outer circumferential surface of the magnetic core 32. Note that the base body 50 does not need to completely cover the entire outer periphery of the magnetic core 32, and a portion of the magnetic core 32 may be exposed from the base body 50.

[0065] Furthermore, the base body 50 can be larger than the mounting hole 22h and can cover the outer opening of the mounting hole 22h to block it. The base body may fit into the mounting hole to block it. The base body may have a portion that blocks the outer opening of the mounting hole and a portion that fits into the mounting hole.

[0066] The base body 50 has a fixing piece 51 for fixing to the rotating electric machine 20. The fixing piece 51 is, for example, a portion in which a screw insertion hole for screw fastening is formed. The fixing piece 51 is formed so as to protrude from the outer periphery of the base body 50. For example, a fixing piece 51 is formed so as to protrude outward from each of both longitudinal end portions of the base body 50. Then, with the base body 50 placed in a portion of the case 22 around the outer opening of the mounting hole 22h, a screw is inserted into the screw insertion hole of the fixing piece 51 and the base body 50 is screwed to the case 22. An annular seal portion that seals the gap between the base body 50 and the case 22 may be interposed.

[0067] The base body 50 may be formed of a single insulating part or multiple insulating parts. Whether the base body 50 is formed of multiple insulating parts may be determined based on whether the base body 50 includes parts that have been separately molded. For example, even if the base body 50 is tightly integrated, if there are boundaries or traces that indicate that the parts have been separately molded, the base body 50 is considered to be formed of multiple insulating parts.

[0068] In this embodiment, the base body 50 includes a first part 60 and a second part 52 .

[0069] The first part 60 is a part that maintains a fixed positional relationship between the terminal 40 and the magnetic core 32. Therefore, by holding the portion of the terminal 40 that protrudes from the first part 60, the magnetic core 32 is supported in a fixed position relative to the terminal 40. When molding the second part 52, by supporting the terminal 40 in a fixed position within the mold, the magnetic core 32 can be supported in a fixed position. In this case, it is not necessary to support the magnetic core 32 by directly contacting it. Therefore, the entire magnetic core 32 can be easily covered.

[0070] Furthermore, because the first component 60 maintains a constant positional relationship between the terminals 40 and the magnetic core 32, the constant positional relationship between the terminals 40 and the magnetic core 32 is likely to be maintained even after the second component 52 is molded. This makes it easier to ensure the desired noise reduction effect of the magnetic core 32.

[0071] Furthermore, by interposing the first component 60 between the terminal 40 and the magnetic core 32, insulation between the terminal 40 and the magnetic core 32 is easily ensured.

[0072] The second component 52 covers the magnetic core 32 while filling the gap between the terminal 40 and the magnetic core 32 .

[0073] That is, while the first part 60 maintains a fixed positional relationship between the terminal 40 and the magnetic core 32, the second part 52, which is molded separately from the first part 60, fills the gap between the terminal 40 and the magnetic core 32. This prevents a gap filled with gas from occurring between the terminal 40 and the magnetic core 32.

[0074] Furthermore, by molding the second component 52 separately from the first component 60, the magnetic core 32 can be covered more completely.

[0075] The first component 60 will now be described in more detail.

[0076] The first part 60 is a part integrally formed from resin by molding. There are no boundaries or traces within the first part 60 that would indicate that it was formed by molding separately.

[0077] The first component 60 has an enclosing portion 62 that surrounds the terminals 40 within the magnetic core 32. In this embodiment, the enclosing portion 62 is formed in a flat rectangular parallelepiped shape so as to surround all of the terminals 40 that are lined up in a row. Of the sides of the enclosing portion 62, the edges corresponding to the sides that extend in the same direction as the longitudinal direction of the terminals 40 may be rounded.

[0078] The thickness of the surrounding portion 62 is smaller than the dimension in the short direction of the annular inner peripheral surface of the magnetic core 32. The width of the surrounding portion 62 is smaller than the dimension in the long direction of the annular inner peripheral surface of the magnetic core 32. Therefore, the surrounding portion 62 can fit inside the magnetic core 32, and a gap can be created between the periphery of the surrounding portion 62 and the inner peripheral surface of the magnetic core 32 inside the magnetic core 32.

[0079] The height of the surrounding portion 62 in the direction along the longitudinal direction of the terminal 40 is preferably equal to or greater than the height of the magnetic core 32. In this case, the surrounding portion 62 can more reliably insulate the magnetic core 32 and the terminal 40.

[0080] The terminal 40 penetrates both ends of the surrounding portion 62 and protrudes upward and downward. A through hole into which the terminal 40 can be press-fitted may be formed in the surrounding portion 62, and the terminal 40 may be press-fitted into the through hole. The first component 60 may be molded using the middle portion of the terminal 40 as an insert portion. In either case, the gap between the surrounding portion 62 and the terminal 40 can be reduced.

[0081] The first component 60 may have a partial protrusion 63 that partially protrudes from the outer circumferential surface of the surrounding portion 62. The partial protrusion 63 is set to a protrusion amount that allows it to come into contact with the inner circumferential surface of the magnetic core 32.

[0082] In this embodiment, partial protrusions 63 are formed on both thickness-wise surfaces of the surrounding portion 62. More specifically, a plurality of (here, three) partial protrusions 63 are formed at intervals on each of the thickness-wise surfaces of the surrounding portion 62.

[0083] The partial protrusions 63 on both thickness-wise surfaces of the surrounding portion 62 contact the inner peripheral surface of the magnetic core 32 , positioning the surrounding portion 62 at the midpoint in the lateral direction of the annular inner peripheral surface of the magnetic core 32 .

[0084] To the extent that the tips of the partial protrusions 63 can be deformed when the surrounding portion 62 is inserted into the magnetic core 32, the distance between the tips of the partial protrusions 63 on both sides of the surrounding portion 62 in the thickness direction is preferably greater than the distance in the short direction of the annular inner peripheral surface of the magnetic core 32. The tips of the partial protrusions 63 are preferably formed thinner than the intermediate portion in the protruding direction so that they can be deformed more easily than the intermediate portion.

[0085] As a result, even if an error occurs in the surrounding portion 62 or the magnetic core 32, the tip of the partial protrusion 63 can be deformed and brought into contact with the inner circumferential surface of the magnetic core 32. As a result, even if an error occurs in the surrounding portion 62 or the magnetic core 32, the surrounding portion 62 and the terminal 40 can be accurately positioned with respect to the magnetic core 32.

[0086] Additionally, a gap is provided between the outer peripheral surface of the surrounding portion 62 and the inner peripheral surface of the magnetic core 32 around the partial protrusion 63. If the gap between the surrounding portion 62 and the magnetic core 32 is small, the resin used to mold the second part 52 will not easily flow into the gap, and a gap may remain between the surrounding portion 62 and the magnetic core 32 in the final product. If a gap large enough to allow the resin to easily flow in is formed between the outer peripheral surface of the surrounding portion 62 and the inner peripheral surface of the magnetic core 32, the resin used to mold the second part 52 will easily flow into the gap, and the gap between the surrounding portion 62 and the magnetic core 32 in the final product will be reduced.

[0087] The partial protrusions 63 may be elongated along the longitudinal direction of the terminal 40. If the partial protrusions 63 are elongated along the longitudinal direction of the terminal 40, resin flowing in from the openings on both end faces of the magnetic core 32 can be easily introduced between the surrounding portion 62 and the magnetic core 32. For example, resin flowing in from the openings on both end faces of the magnetic core 32 can smoothly flow between the surrounding portion 62 and the magnetic core 32 by passing between the multiple partial protrusions 63 arranged in parallel.

[0088] If the partial protrusion 63 has a long shape along the longitudinal direction of the terminal 40, the partial protrusion 63 is less likely to get caught on the magnetic core 32 when the first component 60 is inserted into the magnetic core 32. Therefore, the first component 60 can be easily inserted into the magnetic core 32.

[0089] The enclosing portion 62 may include an elastic positioning portion 64 including an elongated elastic portion 65a and a locking protrusion 65b.

[0090] The elongated elastic portion 65a is configured to be elastically deformable so as to move toward and away from the inner periphery of the magnetic core 32. The locking protrusion 65b protrudes from the elongated elastic portion 65a. The locking protrusion 65b locks onto the magnetic core 32, so that the first component 60 maintains a fixed positional relationship between the terminal 40 and the magnetic core 32 on one axial side.

[0091] In this embodiment, elastic positioning portions 64 are provided on both sides of the enclosing portion 62 in the longitudinal direction.

[0092] A base portion 65c protrudes from a side portion of the surrounding portion 62 toward one side in the longitudinal direction of the terminal 40. A long elastic portion 65a extends from the base portion 65c along the axial direction of the magnetic core 32. The long elastic portion 65a extends at a distance from the outer peripheral surface of the surrounding portion 62. Therefore, the long elastic portion 65a can elastically deform so as to narrow the distance. In this case, the long elastic portion 65a can elastically deform using the range in which the surrounding portion 62 exists in the longitudinal direction of the terminal 40, making it easy to miniaturize the positioning configuration using the elastic positioning portion 64. The long elastic portion may protrude from the surrounding portion in the longitudinal direction of the terminal.

[0093] The locking projection 65b protrudes outward from the tip of the elastic positioning portion 64. In the longitudinal direction of the terminal 40, the locking projection 65b is located at one end of the surrounding portion 62, and is located at a position where it can be locked onto one end face of the magnetic core 32 when the first component 60 is disposed inside the magnetic core 32.

[0094] The surface of the locking protrusion 65b facing the tip of the elongated elastic portion 65a is an inclined surface that gradually increases the protrusion amount of the locking protrusion 65b. The surface of the locking protrusion 65b facing the base end of the elongated elastic portion 65a is a surface that is perpendicular to the longitudinal direction of the elongated elastic portion 65a.

[0095] The first component 60 may have an end face positioning protrusion 66 that protrudes from the outer circumferential surface of the surrounding portion 62 and abuts against the end face of the magnetic core 32 .

[0096] In this embodiment, end face positioning protrusions 66 are provided on both sides of the enclosing portion 62 in the longitudinal direction.

[0097] As described above, the base portion 65c protrudes from the side of the surrounding portion 62 toward one side in the longitudinal direction of the terminal 40. The end face positioning projection 66 is formed so as to protrude further from the base portion 65c.

[0098] That is, in the longitudinal direction of the terminal 40, the locking protrusion 65b is located on one end side of the surrounding portion 62, and the end face positioning protrusion 66 is located on the other end side. A gap corresponding to the distance between the end faces of the magnetic core 32 is provided between the locking protrusion 65b and the end face positioning protrusion 66.

[0099] Therefore, the locking projection 65b can contact one end face of the magnetic core 32, and the end face positioning projection 66 can contact the other end face of the magnetic core 32. This positions the first component 60 and the terminal 40 relative to the magnetic core 32 on both axial sides of the magnetic core 32.

[0100] FIG. 7 is an explanatory diagram showing an example of an operation for inserting the first component 60 that holds the terminal 40 into the magnetic core 32. As shown in FIG.

[0101] As shown in the figure, a first component 60 for holding a terminal 40 is prepared. One end of the terminal 40 is inserted into the magnetic core 32, and the elastic positioning portions 64 on both sides of the first component 60 are pressed against the opening edge of the magnetic core 32. Then, the inclined surfaces of the locking projections 65b come into contact with the opening edge of the magnetic core 32, and the elongated elastic portions 65a are elastically deformed inward. This causes the locking projections 65b to fit inside the inner circumferential surface of the magnetic core 32, allowing the first component 60 to be inserted into the magnetic core 32 (see the elastic positioning portions 64 indicated by the two-dot chain line in FIG. 7).

[0102] When the first component 60 is further pressed in, the end face positioning protrusion 66 engages with one end face of the magnetic core 32. At the same time, the locking protrusion 65b passes over the inner peripheral surface of the magnetic core 32 and returns to its original position due to its own elastic restoring force. As a result, the locking protrusion 65b engages with the other end face of the magnetic core 32 from the side opposite the end face positioning protrusion 66 (see the elastic positioning portion 64 indicated by the dashed line in FIG. 7).

[0103] As a result, the first component 60 is positioned relative to the magnetic core 32 from both sides of the terminal 40 in the longitudinal direction.

[0104] In the above state, the partial protrusion 63 contacts the inner peripheral surface of the magnetic core 32 in the short direction of the annular inner peripheral surface of the magnetic core 32. Furthermore, the bases 65c on both longitudinal sides of the first component 60 contact the inner peripheral surface of the magnetic core 32 in the long direction of the annular inner peripheral surface of the magnetic core 32. This positions the terminal 40 relative to the magnetic core 32 also in the direction perpendicular to the long direction of the terminal 40.

[0105] <Example of manufacturing method> An example of a method for manufacturing the terminal block 30 will be described with reference to FIG.

[0106] First, the magnetic core 32 is positioned relative to the terminal 40 so that the magnetic core 32 surrounds the terminal 40 with a gap therebetween. For example, the magnetic core 32 is positioned relative to the terminal 40 by attaching the first component 60 that holds the terminal 40 to the magnetic core 32 (see FIG. 5).

[0107] An injection molding die 80 is prepared that has a die surface 82 that forms the surface shape of the second component 52 and a set portion 84 that holds the portion of the terminal 40 that protrudes from the base body 50.

[0108] By setting the terminal 40 in the setting portion 84 of the mold 80, the magnetic core 32 is placed in the mold space 82S surrounded by the mold surface 82. At this time, because the terminal 40 is set in the setting portion 84 of the mold 80, the magnetic core 32 can be placed in the space surrounded by the magnetic core 32 and the mold surface 82 without being positioned.

[0109] Then, the resin, which has been softened or melted by heating and is in a fluid state, is injected into the mold space 82S through the injection port 80h. The injected resin flows between the magnetic core 32 and the mold surface 82, forming the outer shape of the base body 50 surrounding the magnetic core 32. The injected resin fills the gap between the terminal 40 and the magnetic core 32. More specifically, the injected resin reaches the end face of the magnetic core 32 and flows into the magnetic core 32 through the end face opening. The resin also flows into the gap between the first component 60 and the annular inner surface of the magnetic core 32, filling the gap. In other words, the gap between the terminal 40 and the magnetic core 32, except for the space occupied by the first component 60, is filled with resin. This reduces the likelihood of a gas-filled gap remaining between the terminal 40 and the magnetic core 32.

[0110] <Effects, etc.> According to the terminal block 30 configured as described above, the block body 50 is filled between the terminal 40 and the magnetic core 32. This allows the terminal 40 to be held in a fixed position relative to the magnetic core 32. Furthermore, the gap between the magnetic core 32 and the terminal 40 is reduced. This reduces rattle of the terminal 40 and the magnetic core 32. Furthermore, the presence of an air gap in the terminal block 30 can be reduced, which reduces heat buildup due to the presence of the air gap. This allows heat generated by the terminal 40 or the magnetic core 32 to be effectively dissipated.

[0111] Furthermore, since the position of the terminal 40 relative to the magnetic core 32 is stable, the noise reduction effect of the magnetic core 32 is stable.

[0112] Furthermore, in recent years, the need for noise countermeasures has increased due to the increasing use of high-voltage drive systems in vehicles and the widespread use of SiC semiconductors. Therefore, by using a nanocrystalline magnetic core with high magnetic permeability as the magnetic core 32, noise countermeasures are possible while ensuring compactness and heat resistance. It is also suitable for use in high-temperature environments. Furthermore, by reducing the gap between the terminal 40 and the magnetic core 32 made of the nanocrystalline magnetic core, deformation of the nanocrystalline magnetic core due to the gap can be suppressed.

[0113] Furthermore, the base body 50 includes a first part 60 and a second part 52, and the first part 60 maintains a fixed positional relationship between the terminal 40 and the magnetic core 32. In other words, the first part is a positioning part. Therefore, if the terminal 40 is supported in a fixed position, the magnetic core 32 is maintained in a fixed position. In this state, the second part 52 can be easily molded.

[0114] Furthermore, since the first component 60 includes the surrounding portion 62, the surrounding portion 62 can easily insulate the magnetic core 32 and the terminal 40 from each other.

[0115] Furthermore, since the first component 60 has the partial protrusion 63, contacting the partial protrusion 63 with the inner circumferential surface of the magnetic core 32 makes it easy to form a gap between the surrounding portion 62 and the magnetic core 32 into which the resin can easily flow. Therefore, a gap is unlikely to remain between the surrounding portion 62 and the magnetic core 32.

[0116] Furthermore, since the partial protrusion 63 has an elongated shape along the longitudinal direction of the terminal 40, it is easy to pour the resin between the surrounding portion 62 and the magnetic core 32 along the longitudinal direction of the terminal 40. As a result, a gap is unlikely to remain between the surrounding portion 62 and the magnetic core 32.

[0117] The first component 60 also has a long elastic portion 65a and a locking protrusion 65b. The elastic deformation of the long elastic portion 65a can be used to lock the locking protrusion 65b to the magnetic core 32. This makes it difficult for a large force to be applied to the magnetic core 32 during positioning, and the magnetic core 32 is less likely to be distorted.

[0118] Furthermore, when the elongated elastic portion 65a extends with a gap from the outer peripheral surface of the surrounding portion 62, the elongated elastic portion 65a can smoothly elastically deform to reduce the gap, which makes it difficult for a large force to be applied to the magnetic core 32, and the magnetic core 32 becomes less likely to be distorted.

[0119] In particular, when the magnetic core 32 is a nanocrystalline magnetic core, the nanocrystalline magnetic core may be easily deformed. Deformation of the nanocrystalline magnetic core may cause fluctuations in noise reduction performance. Therefore, as described above, by adopting a configuration that allows the first component 60 to be locked to the magnetic core 32 while suppressing distortion of the magnetic core 32, the desired noise reduction effect can be easily achieved.

[0120] Furthermore, if the first component 60 has end face positioning projections 66 that protrude from the surrounding portion 62 and abut against the end faces of the magnetic core 32, the terminals 40 can be easily positioned at fixed positions relative to the magnetic core 32 in the longitudinal direction thereof.

[0121] Furthermore, when manufacturing the terminal block 30, the terminal 40 is set in the mold 80, so that the magnetic core 32 can be placed in the mold space 82S of the mold 80. Then, a resin in a fluid state is injected into the mold space 82S, filling the space between the terminal 40 and the magnetic core 32 with the resin, and the block main body 50 surrounding the magnetic core 32 can be mold-molded.

[0122] Therefore, the entire periphery of the magnetic core 32 can be easily positioned away from the mold surface 82, allowing resin to be smoothly filled between the terminal 40 and the magnetic core 32. This allows the terminal 40 to be held in a fixed position relative to the magnetic core 32. Also, it is possible to reduce gaps between the magnetic core 32 and the terminal 40. Furthermore, a structure for positioning the magnetic core in the mold can be omitted, simplifying the mold structure and the manufacturing process.

[0123] Furthermore, after the second part 52 is molded, no marks of the positioning pins of the magnetic core 32 remain on the second part 52, and the magnetic core 32 can be covered more completely by the second part 52.

[0124] The configurations described in the above embodiment and modifications can be combined as appropriate as long as they are not mutually inconsistent. [Explanation of symbols]

[0125] 10. Electromechanical integrated unit 12 inverters 18 Bus Bar 20 Rotating Electric Machine 22 cases 22h Mounting hole 24 Armature 26 Coil connection end 28 Field magnet 30 Terminal block 32 Magnetic core 40 terminals 42 first connection end 42h First screw insertion hole 46 Second connection end 46h Second screw insertion hole 50 units 51 Fixed piece 52 Second Part 60 First part (positioning part) 62 Encirclement 63 Partial protrusion 64 Elastic positioning part 65a Long elastic part 65b Locking protrusion 65c base 66 End face positioning protrusion 80 Injection mold 80h inlet 82 Mold surface 82S mold space 84 Set Section

Claims

1. A positioning component that maintains a constant positional relationship between a terminal and a magnetic core that surrounds the terminal with a gap therebetween, an enclosing portion that encloses the terminal within the magnetic core; A positioning component including a partial protrusion that partially protrudes from the outer peripheral surface of the surrounding portion and contacts the inner peripheral surface of the magnetic core.

2. The positioning component according to claim 1 , The partial protrusion is elongated along the longitudinal direction of the terminal.

3. The positioning component according to claim 1 or 2, a long elastic portion that elastically deforms to approach and move away from an inner circumferential portion of the magnetic core; and a locking projection that projects from the long elastic portion, The locking projection is locked to the magnetic core, thereby maintaining a constant positional relationship between the terminal and the magnetic core.

4. The positioning component according to claim 3, The elongated elastic portion extends at a distance from the outer peripheral surface of the surrounding portion.

5. The positioning component according to claim 1 or 2, A positioning component including an end face positioning protrusion that protrudes from the outer peripheral surface of the surrounding portion and abuts against the end face of the magnetic core.

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