Case and brake control device

Abstract

To obtain a case capable of reducing stress as an example.SOLUTION: A case according to an embodiment includes a metal plate configured to have a first surface facing a heat-generating internal component, a second surface located on a side opposite to the first surface, and an outer peripheral surface connected to an edge of an outer periphery of the first surface and an edge of an outer periphery of the second surface, the metal plate being configured to be thermally connected to the component, and a resin-made casing member having a contact surface that comes into contact with the second surface, and an inner peripheral surface that surrounds the outer peripheral surface and is partially in contact with and partially separated from the outer peripheral surface.SELECTED DRAWING: Figure 2

Description

[Technical Field]

[0001] FIELD An embodiment of the present invention relates to a case and a brake control device. [Background technology]

[0002] Conventionally, various devices, such as a brake control device, have heat-generating components and a case to house the components in. The components can dissipate heat by being thermally connected to a metal case (Patent Document 1). [Prior art documents] [Patent documents]

[0003] [Patent Document 1] Japanese Patent Application Laid-Open No. 2006-049501 Summary of the Invention [Problem to be solved by the invention]

[0004] The case may have an integrated metal portion and a resin portion, for example, manufactured by insert molding. However, metal and resin have different thermal expansion coefficients. For example, in a low-temperature environment, the resin portion may shrink more than the metal portion, causing stress in the resin portion.

[0005] Therefore, the present invention has been made in view of the above, and provides a case that can reduce stress, and a brake control device that includes the case. [Means for solving the problem]

[0006] A case according to an embodiment of the present invention includes, for example, a metal plate having a first surface facing an internal component that generates heat, a second surface located opposite the first surface, and an outer peripheral surface connected to the outer peripheral edge of the first surface and the outer peripheral edge of the second surface, configured to be thermally connected to the component; and a resin casing member integrated with the metal plate, the resin casing member having a contact surface in contact with the second surface and an inner peripheral surface surrounding the outer peripheral surface and partially contacting the outer peripheral surface and partially spaced apart from the outer peripheral surface. Thus, for example, by integrating the resin casing member with the metal plate, a case capable of efficiently dissipating heat from the component is obtained. Because the casing member is made of resin, its coefficient of thermal expansion differs from that of the metal plate. Therefore, for example, in a low-temperature environment, the casing member shrinks more than the metal plate, causing the inner peripheral surface to press against the outer peripheral surface. However, because the inner peripheral surface is partially spaced apart from the outer peripheral surface, the metal plate pressed against the inner peripheral surface may move relative to the casing member, or a portion of the casing member may expand into the gap between the inner peripheral surface and the outer peripheral surface. Therefore, compared to when the inner peripheral surface is in contact with the entire outer peripheral surface, the stress of the casing member due to contact with the metal plate when it contracts can be reduced. [Brief explanation of the drawings]

[0007] [Figure 1] FIG. 1 is a cross-sectional view that schematically illustrates a brake system according to one embodiment. [Figure 2] FIG. 2 is a cross-sectional view showing the ECU of the embodiment. [Figure 3] FIG. 3 is a plan view showing the cover of the embodiment. DETAILED DESCRIPTION OF THE INVENTION

[0008] An embodiment will be described below with reference to FIGS. 1 to 3. In this specification, components according to the embodiment and descriptions of the components may be described using multiple expressions. The components and their descriptions are merely examples and are not limited by the expressions in this specification. The components may also be identified by names different from those in this specification. Furthermore, the components may also be described using expressions different from those in this specification.

[0009] In the following description, "suppress" is defined as, for example, preventing an event, action, or influence from occurring, or reducing the severity of an event, action, or influence. Also, in the following description, "restrict" is defined as, for example, preventing movement or rotation, or allowing movement or rotation within a predetermined range and preventing movement or rotation beyond the predetermined range.

[0010] 1 is a cross-sectional view that schematically shows a brake system 10 according to this embodiment. The brake system 10 is mounted on a vehicle 1 such as a four-wheeled automobile. However, the brake system 10 is not limited to this example.

[0011] The brake system 10 includes a brake control device 11 and a plurality of wheel cylinders 12. The brake control device 11 may also be referred to as a brake fluid pressure control device. The brake system 10 may further include various other components such as a master cylinder, a pump, and a solenoid valve.

[0012] The brake control device 11 controls, for example, the hydraulic pressure of at least one of the plurality of wheel cylinders 12. The brake control device 11 includes an electric cylinder device 21, an electronic control unit (ECU) 22, and a plurality of hydraulic paths 23.

[0013] The electric cylinder device 21 is connected to at least one of the plurality of wheel cylinders 12 via a fluid path 23. The electric cylinder device 21 can increase the pressure of the brake fluid in the wheel cylinder 12 to generate a braking force for the vehicle 1.

[0014] The electric cylinder device 21 has a motor 25 and a pressure adjusting device 26. The motor 25 is an example of an actuator. However, the actuator is not limited to the motor 25, and may be another actuator such as a solenoid actuator.

[0015] The motor 25 is, for example, a three-phase brushless motor. However, other types of motors may be used as the motor 25. The motor 25 is controlled by the ECU 22, for example, to drive the pressure regulator 26.

[0016] The pressure regulating device 26 includes a housing 31, a piston 32, two seals 33 and 34, a reservoir 35, a rotary-to-linear motion conversion mechanism 36, and a speed reduction mechanism 37. The ECU 22 and the motor 25 are located outside the housing 31. However, the ECU 22 and the motor 25 may be located inside the housing 31.

[0017] An internal space 41 is provided inside the housing 31. The internal space 41 is a substantially cylindrical space extending along a central axis Axc. The central axis Axc is, for example, a virtual central axis of the internal space 41. Note that the central axis of the internal space 41 may be different from the central axis Axc.

[0018] For convenience, the axial direction and the radial direction are defined herein. The axial direction is a direction along the central axis Axc. The axial direction includes a forward direction Df and a rearward direction Db. The forward direction Df is a direction along the central axis Axc. The rearward direction Db is the opposite direction to the forward direction Df. The radial direction is a direction perpendicular to the central axis Axc.

[0019] The housing 31 is further provided with an output port 42 and an input port 43. The output port 42 and the input port 43 each communicate with the internal space 41. In the axial direction, the output port 42 is spaced apart from the input port 43 in the forward direction Df.

[0020] The piston 32 is disposed in the internal space 41. The piston 32 is able to move axially within the internal space 41. The piston 32 defines a portion of the internal space 41 as a fluid chamber 45. That is, the fluid chamber 45 is provided in the pressure adjusting device 26. The fluid chamber 45 is provided axially between the piston 32 and the end of the internal space 41 in the forward direction Df. The fluid chamber 45 is filled with brake fluid. In other words, the fluid chamber 45 contains brake fluid.

[0021] The output port 42 is connected to a fluid chamber 45. The fluid chamber 45 is connected to the wheel cylinder 12 through the output port 42 and the fluid passage 23. The piston 32 reduces the volume of the fluid chamber 45 by moving forward Df. This allows the electric cylinder device 21 to increase the pressure of the brake fluid in the fluid chamber 45 and the wheel cylinder 12.

[0022] On the other hand, the piston 32 moves in the rear direction Db to increase the volume of the fluid chamber 45. This allows the electric cylinder device 21 to reduce the pressure of the brake fluid in the fluid chamber 45 and the wheel cylinder 12.

[0023] A gap is provided between the housing 31 and the piston 32 in the radial direction, allowing the piston 32 to move axially relative to the housing 31. Two seals 33, 34 seal the gap.

[0024] The seal 33 is spaced from the seal 34 in the forward direction Df. In the axial direction, the output port 42 communicates with the liquid chamber 45 at a position spaced from the seal 33 in the forward direction Df. In the axial direction, the input port 43 communicates with the internal space 41 between the two seals 33, 34. The seal 33 seals between the liquid chamber 45 and the input port 43.

[0025] The reservoir 35 is connected to the input port 43 through the fluid path 23. The reservoir 35 stores brake fluid. For example, the reservoir 35 is open to the atmosphere, so that the pressure of the reservoir 35 is maintained at atmospheric pressure.

[0026] When the piston 32 moves rearward Db beyond a predetermined position, the input port 43 and the fluid chamber 45 communicate with each other. This allows the brake fluid to flow freely between the fluid chamber 45 and the reservoir 35, and the pressure in the fluid chamber 45 drops to atmospheric pressure.

[0027] The rotary-to-linear motion conversion mechanism 36 is disposed in the internal space 41. In this embodiment, the rotary-to-linear motion conversion mechanism 36 is, for example, a ball screw. The rotary-to-linear motion conversion mechanism 36 has a rotating member 51, a linear motion member 52, and a plurality of balls 53.

[0028] The rotating member 51 is formed in a generally cylindrical shape extending along the central axis Axc. The linear moving member 52 is formed in a generally cylindrical shape extending along the central axis Axc. The rotating member 51 extends through a hole inside the linear moving member 52. The linear moving member 52 is attached to or supports the piston 32.

[0029] A male screw is provided on the rotating member 51. On the other hand, a female screw is provided on the linear moving member 52. The linear moving member 52 may further be provided with a circulation path connecting both ends of the female screw. The plurality of balls 53 are, for example, held by the female screw of the linear moving member 52 so as to be able to roll and circulate, and are fitted into the male screw of the rotating member 51. Therefore, the linear moving member 52 is attached to the rotating member 51 via the balls 53.

[0030] The speed reduction mechanism 37 has a plurality of gears that mesh with each other. The speed reduction mechanism 37 is not limited to the example shown in Figure 1, and may be another speed reduction mechanism such as a planetary gear mechanism. The speed reduction mechanism 37 is provided between the motor 25 and the rotating member 51.

[0031] The motor 25 rotates the rotating member 51 around the central axis Axc through the speed reduction mechanism 37. The speed reduction mechanism 37 may be omitted. For example, the motor 25 may rotate the rotating member 51 directly.

[0032] When the motor 25 rotates the rotating member 51 in one direction (forward direction) around the central axis Axc, the rotating member 51 pushes the linearly moving member 52 in the forward direction Df via the ball 53. Furthermore, the linearly moving member 52 pushes the piston 32 in the forward direction Df. As a result, the linearly moving member 52 and the piston 32 move (advance) in the forward direction Df. By moving in the forward direction Df, the piston 32 reduces the volume of the liquid chamber 45 and increases the pressure in the liquid chamber 45.

[0033] On the other hand, when the motor 25 rotates the rotating member 51 in the direction opposite to the forward rotation direction (reverse direction), the rotating member 51 pushes the linearly moving member 52 in the rearward direction Db via the ball 53. The piston 32 moves (retracts) in the rearward direction Db together with the linearly moving member 52. By moving in the rearward direction Db, the piston 32 increases the volume of the liquid chamber 45 and reduces the pressure in the liquid chamber 45. As described above, the pressure adjusting device 26 is driven by the motor 25 to change the pressure in the liquid chamber 45.

[0034] 2 is a cross-sectional view showing the ECU 22 of this embodiment. As shown in each drawing, for convenience, an X-axis, a Y-axis, and a Z-axis are defined in this specification. The X-axis, the Y-axis, and the Z-axis are perpendicular to one another. The X-axis is set along the width of the ECU 22. The Y-axis is set along the depth of the ECU 22. The Z-axis is set along the thickness of the ECU 22.

[0035] Furthermore, in this specification, the X direction, Y direction, and Z direction are defined. The X direction is a direction along the X axis, and includes the +X direction indicated by the X axis arrow and the -X direction opposite to the X axis arrow. The Y direction is a direction along the Y axis, and includes the +Y direction indicated by the Y axis arrow and the -Y direction opposite to the Y axis arrow. The Z direction is a direction along the Z axis, and includes the +Z direction indicated by the Z axis arrow and the -Z direction opposite to the Z axis arrow.

[0036] The ECU 22 has a circuit board 61, a case 62, and a plurality of heat transfer members 63. In Fig. 2, the heat transfer members 63 are schematically indicated by two-dot chain lines. The circuit board 61 is an example of a component.

[0037] The circuit board 61 includes a substrate 71, a plurality of power transistors 72, and a plurality of heat sinks 73. The circuit board 61 further includes a microcontroller, an inverter circuit, sensors, capacitors, and various other components.

[0038] The substrate 71 is, for example, a printed wiring board. The substrate 71 has two substantially flat surfaces 71a and 71b. The surface 71a faces substantially in the -Z direction. The surface 71b is located on the opposite side of the substrate 71 from the surface 71a (the opposite side of the substrate 71) and faces substantially in the +Z direction.

[0039] The power transistor 72 is mounted on the surface 71a. The heat sink 73 is mounted on the surface 71b. Other components may be mounted on either the surface 71a or 71b, or may be provided inside the substrate 71. The substrate 71 further has wiring provided on the surfaces 71a and 71b and inside the substrate 71.

[0040] The power transistor 72 is, for example, a metal oxide semiconductor field effect transistor (MOSFET). However, the power transistor 72 is not limited to this example. The power transistor 72 is electrically connected to the motor 25 via, for example, an inverter circuit on the circuit board 61.

[0041] The power transistor 72 switches the power supply to the motor 25. Therefore, the motor 25 is supplied with power from the power transistor 72. The power transistor 72 generates heat when power is supplied to the motor 25.

[0042] The heat sink 73 is thermally connected to the power transistor 72. The heat sink 73 may be formed integrally with the power transistor 72. The heat sink 73 cools the power transistor 72 by thermal conduction.

[0043] The case 62 is formed in a substantially rectangular box shape. However, the shape of the case 62 is not limited to this example. An accommodation chamber 81 is provided inside the case 62. The circuit board 61 and the heat transfer member 63 are accommodated in the accommodation chamber 81 of the case 62. In other words, the circuit board 61 and the heat transfer member 63 are components inside the case 62. The case 62 has a base 85 and a cover 86.

[0044] The base 85 is attached to the housing 31 of the pressure adjusting device 26 by, for example, screws. The base 85 has a resin base 91, a plurality of internal terminals 92, and an external terminal 93. However, the base 85 is not limited to this example.

[0045] The resin base 91 is a component made of resin. The resin base 91 is formed in a box shape that is open in the +Z direction. The resin base 91 has an inner surface 91a and an outer surface 91b. The inner surface 91a defines a part of the accommodation chamber 81. The inner surface 91a faces the circuit board 61 accommodated in the accommodation chamber 81. The outer surface 91b is located on the opposite side of the inner surface 91a (the opposite side of the resin base 91) and is located outside the case 62.

[0046] The internal terminals 92 and external terminals 93 are, for example, metal pins. The internal terminals 92 protrude from the inner surface 91a. The internal terminals 92 are, for example, electrically connected to wiring on the substrate 71. The external terminals 93 protrude from the outer surface 91b.

[0047] The external terminal 93 is electrically connected to the internal terminal 92, for example, through a conductor embedded in the resin base 91. Furthermore, the external terminal 93 is electrically connected to the motor 25 through wiring outside the case 62. In this way, the circuit board 61 is electrically connected to the motor 25. For example, the microcontroller on the circuit board 61 drives the motor 25 by supplying power to the motor 25 from the power transistor 72.

[0048] 3 is a plan view showing the cover 86 of this embodiment. As shown in FIG. 3, the cover 86 has a metal plate 101 and a resin cover 102. The metal plate 101 may also be referred to as a heat sink. The resin cover 102 is an example of a casing member.

[0049] The metal plate 101 is made of a metal such as an aluminum alloy. As shown in FIG. 2, the metal plate 101 is disposed so as to be substantially perpendicular to the Z direction and is spaced apart from the circuit board 61 in the +Z direction. The metal plate 101 has two substantially flat surfaces 101a and 101b and an outer peripheral surface 101c. The surface 101a is an example of a first surface. The surface 101b is an example of a second surface.

[0050] The surface 101a faces approximately in the -Z direction. The surface 101a faces the circuit board 61. The surface 101a of the metal plate 101 and the surface 71b of the substrate 71 face each other with a gap between them. The surface 101b is located on the opposite side of the surface 101a (the opposite side of the metal plate 101) and faces approximately in the +Z direction.

[0051] The outer peripheral surface 101c is connected to the outer edge of the surface 101a and the outer edge of the surface 101b. The outer peripheral surface 101c faces, for example, in a direction substantially perpendicular to the Z direction. As shown in FIG. 3, the outer peripheral surface 101c has a plurality of linear regions 111, a plurality of angular portions 112, and a recessed region 113.

[0052] Hereinafter, the multiple linear regions 111 may be individually referred to as linear regions 111A, 111B, 111C, 111D, 111E, 111F, 111G, 111H, and 111I. A description common to the multiple linear regions 111A, 111B, 111C, 111D, 111E, 111F, 111G, 111H, and 111I will be described as a description of the linear region 111.

[0053] The corner portions 112 may be individually referred to as corner portions 112A, 112B, 112C, 112D, 112E, 112F, 112G, and 112H. A description common to the corner portions 112A, 112B, 112C, 112D, 112E, 112F, 112G, and 112H will be provided as a description of the corner portion 112.

[0054] The linear regions 111A, 111B, 111C, 111D, and 111E extend linearly in approximately the Y direction. That is, the linear regions 111A, 111B, 111C, 111D, and 111E extend parallel to one another. The linear regions 111A, 111B, and 111C face approximately in the +X direction. The linear regions 111D and 111E face approximately in the -X direction.

[0055] The linear regions 111A and 111B are located on approximately the same plane. The linear region 111E is located on the opposite side of the linear region 111A (the opposite side of the metal plate 101). The linear region 111D is located on the opposite side of the linear regions 111B and 111C. The linear regions 111B and 111D are examples of first parallel regions.

[0056] The linear region 111C is closer to the linear region 111D than the linear regions 111A and 111B. The linear region 111E is closer to the linear regions 111A and 111B than the linear region 111D.

[0057] The linear regions 111F, 111G, 111H, and 111I extend linearly substantially in the X direction. That is, the linear regions 111F, 111G, 111H, and 111I extend parallel to one another. The linear regions 111F and 111G face substantially in the +Y direction. The linear regions 111H and 111I face substantially in the -Y direction.

[0058] The linear regions 111F and 111G are located on the opposite side of the linear region 111H. The linear region 111G is closer to the linear region 111H than the linear region 111F. The linear region 111I is located on the opposite side of the linear region 111G. The linear region 111I is farther away from the linear region 111G than the linear region 111H. The linear regions 111F and 111H are also examples of first parallel regions.

[0059] Each of the plurality of corner portions 112 is provided between two adjacent ones of the plurality of linear regions 111. Each of the plurality of corner portions 112 has an arc-shaped curved surface. However, the corner portions 112 are not limited to this example.

[0060] Corner portion 112A is provided between the end of linear region 111A in the +Y direction and the end of linear region 111F in the +X direction. Corner portion 112B is provided between the end of linear region 111B in the -Y direction and the end of linear region 111H in the +X direction.

[0061] Corner portion 112C is provided between the end of linear region 111E in the +Y direction and the end of linear region 111F in the −X direction. Corner portion 112D is provided between the end of linear region 111E in the −Y direction and the end of linear region 111G in the +X direction.

[0062] Corner portion 112E is provided between the end of linear region 111D in the +Y direction and the end of linear region 111G in the -X direction. Corner portion 112F is provided between the end of linear region 111D in the -Y direction and the end of linear region 111I in the -X direction.

[0063] Corner portion 112G is provided between the end of linear region 111C in the -Y direction and the end of linear region 111I in the +X direction. Corner portion 112H is provided between the end of linear region 111C in the +Y direction and the end of linear region 111H in the -X direction. Note that linear region 111C may be substantially omitted, and corner portions 112G and 112H may be substantially continuous with each other.

[0064] The recessed region 113 is provided between the two linear regions 111A and 111B. The recessed region 113 is recessed in an arc shape in approximately the −X direction from the linear regions 111A and 111B, which are positioned on approximately the same plane.

[0065] In this specification, for convenience, a circumferential direction is defined. The circumferential direction is a direction around the metal plate 101 along the outer circumferential surface 101c. For example, the circumferential direction of the linear region 111A is the Y direction, and the circumferential direction of the linear region 111F is the X direction. Each of the multiple linear regions 111 extends linearly in the circumferential direction. The circumferential direction includes a first circumferential direction Dc1 and a second circumferential direction Dc2.

[0066] The first circumferential direction Dc1 is one direction around the metal plate 101 along the outer circumferential surface 101c. For example, the first circumferential direction Dc1 of the linear region 111A is the +Y direction, the first circumferential direction Dc1 of the linear region 111F is the −X direction, and the first circumferential direction Dc1 of the linear region 111E is the −Y direction.

[0067] The second circumferential direction Dc2 is opposite to the first circumferential direction Dc1. For example, the second circumferential direction Dc2 of the linear region 111A is the −Y direction, the second circumferential direction Dc2 of the linear region 111F is the +X direction, and the second circumferential direction Dc2 of the linear region 111E is the +Y direction.

[0068] The metal plate 101 is provided with knurling 115 and holes 116. The knurling 115 may also be referred to as unevenness. As shown in FIG. 2, the knurling 115 is provided in a region of the surface 101a that faces the power transistor 72 and the heat sink 73. As shown in FIG. 3, the knurling 115 has a plurality of grooves that intersect with each other and a plurality of protrusions formed between the grooves. The holes 116 penetrate the metal plate 101 substantially in the Z direction and open to the surfaces 101a and 101b.

[0069] The resin cover 102 is a component made of resin. Therefore, the resin cover 102 has a lower thermal conductivity than the metal plate 101. The material of the resin cover 102 is, for example, a thermoplastic resin, and is the same as the material of the resin base 91. Note that the material of the resin cover 102 and the material of the resin base 91 may be different from each other.

[0070] 2, the resin cover 102 is formed in a box shape that is open in the −Z direction. The resin cover 102 has an outer wall 121, a peripheral wall 122, and a plurality of claws 123. The claws 123 may also be referred to as gripping portions.

[0071] The outer wall 121 is disposed so as to be substantially perpendicular to the Z direction and is spaced apart from the circuit board 61 in substantially the +Z direction. The outer wall 121 has a substantially flat contact surface 121a. The contact surface 121a faces substantially in the -Z direction. The contact surface 121a comes into contact with substantially the entire surface 101b of the metal plate 101.

[0072] The peripheral wall 122 protrudes from the outer edge of the contact surface 121a in approximately the −Z direction. The peripheral wall 122 surrounds the entire outer peripheral surface 101c of the metal plate 101. The peripheral wall 122 has an end surface 122a and an inner peripheral surface 122b.

[0073] The end surface 122a is provided at the end of the peripheral wall 122 in the -Z direction. The end surface 122a is formed in an endless (annular) shape and is supported by the resin base 91. The end surface 122a is joined to the resin base 91 by, for example, vibration welding. This firmly integrates the resin base 91 and the resin cover 102, and the accommodation chamber 81 is watertightly sealed. The resin cover 102 may be attached to the resin base 91 by other methods.

[0074] The end surface 122a is joined to the resin base 91, whereby the base 85 and the cover 86 define the accommodation chamber 81. In other words, the cover 86 covers the accommodation chamber 81. For example, the accommodation chamber 81 is defined by the inner surface 91a of the base 85, and the surface 101a, contact surface 121a, and inner circumferential surface 122b of the cover 86.

[0075] 3, the inner circumferential surface 122b surrounds the entire outer circumferential surface 101c of the metal plate 101. In other words, the entire outer circumferential surface 101c of the metal plate 101 and the inner circumferential surface 122b of the resin cover 102 face each other. The inner circumferential surface 122b has a separation region 131 and a plurality of contact regions 132.

[0076] Hereinafter, the multiple contact areas 132 may be individually referred to as contact areas 132A, 132B, 132C, 132D, 132E, and 132F. A description common to the multiple contact areas 132A, 132B, 132C, 132D, 132E, and 132F will be described as a description of the contact area 132.

[0077] The separation region 131 is separated from the outer peripheral surface 101c by a gap G. That is, the inner peripheral surface 122b is partially separated from the outer peripheral surface 101c. Note that the separation region 131 may be in temporary contact with the outer peripheral surface 101c.

[0078] The peripheral wall 122 has a plurality of protrusions 135. The plurality of protrusions 135 protrude from the separation region 131 toward the outer peripheral surface 101c of the metal plate 101. A plurality of contact regions 132 are provided at the tips of the plurality of protrusions 135.

[0079] The contact regions 132 are spaced apart from one another in the circumferential direction and are in contact with the outer circumferential surface 101c. That is, the inner circumferential surface 122b is in partial and intermittent contact with the outer circumferential surface 101c. The contact regions 132 are spaced apart from the corner portions 112.

[0080] The contact regions 132A, 132B, and 132C each extend linearly in approximately the Y direction. The contact regions 132A and 132B face approximately the -X direction. The contact region 132A contacts the linear region 111A. The contact region 132B contacts the linear region 111B. The contact region 132C faces approximately the +X direction and contacts the linear region 111D. The contact regions 132B and 132C are examples of second parallel regions.

[0081] The contact regions 132D, 132E, and 132F each extend linearly in approximately the X direction. The contact regions 132D and 132E face approximately in the -Y direction. The contact region 132D contacts the linear region 111F. The contact region 132E contacts the linear region 111G. The contact region 132F faces approximately in the +Y direction. The contact region 132F contacts the linear region 111H. The contact regions 132D, 132E, and 132F are also examples of second parallel regions.

[0082] 3, perpendicular lines LA, LB, LC, LD, LE, and LF are virtually set in the multiple contact areas 132A, 132B, 132C, 132D, 132E, and 132F. The perpendicular lines LA, LB, LC, LD, LE, and LF may also be referred to as normal lines.

[0083] The perpendicular line LA is a perpendicular line to the center of the contact area 132A in the circumferential direction (Y direction). If the contact area 132A is a curved surface, the perpendicular line LA is perpendicular to the tangent to the center of the contact area 132A in the circumferential direction. The perpendicular line LB is a perpendicular line to the center of the contact area 132B in the circumferential direction (Y direction). The perpendicular line LC is a perpendicular line to the center of the contact area 132C in the circumferential direction (Y direction).

[0084] The perpendicular line LD is a perpendicular line to the center of the circumferential direction (X direction) of the contact region 132D. The perpendicular line LE is a perpendicular line to the center of the circumferential direction (X direction) of the contact region 132E. The perpendicular line LF is a perpendicular line to the center of the circumferential direction (X direction) of the contact region 132F.

[0085] The perpendicular lines LA, LB, LC, LD, LE, and LF do not coincide with the other perpendicular lines LA, LB, LC, LD, LE, and LF. In other words, the perpendicular lines LA, LB, LC, LD, LE, and LF are not collinear. In this embodiment, the perpendicular lines LA, LB, and LC are spaced apart from one another in the Y direction. Furthermore, the perpendicular lines LD, LE, and LF are spaced apart from one another in the X direction.

[0086] As described above, the contact regions 132A, 132B, and 132C extend substantially in the Y direction. In the Y direction, the contact regions 132A, 132B, and 132C are at least partially located at different positions from one another. In this embodiment, the contact regions 132A, 132B, and 132C are located at positions spaced apart from one another in the Y direction. That is, the two contact regions 132A and 132C do not face each other, and the two contact regions 132B and 132C do not face each other.

[0087] As described above, the contact regions 132D, 132E, and 132F extend substantially in the X direction. In the X direction, the contact regions 132D, 132E, and 132F are at least partially in different positions from one another. In this embodiment, the contact regions 132D, 132E, and 132F are spaced apart from one another in the X direction. That is, the two contact regions 132D and 132F do not face each other, and the two contact regions 132E and 132F do not face each other.

[0088] The perpendicular line LA is spaced from the center of the linear region 111A in the Y direction in the first circumferential direction Dc1 (+Y direction). The perpendicular line LB is spaced from the center of the linear region 111B in the Y direction in the first circumferential direction Dc1 (+Y direction). The perpendicular line LC is spaced from the center of the linear region 111D in the Y direction in the first circumferential direction Dc1 (-Y direction).

[0089] The perpendicular line LD is spaced apart in the first circumferential direction Dc1 (-X direction) from the center of the linear region 111F in the X direction. The perpendicular line LE is spaced apart in the first circumferential direction Dc1 (-X direction) from the center of the linear region 111G in the X direction. The perpendicular line LF is spaced apart in the first circumferential direction Dc1 (+X direction) from the center of the linear region 111H in the X direction.

[0090] Two of the perpendicular lines LA, LB, LC, LD, LE, and LF intersect with each other. However, in this embodiment, three or more of the perpendicular lines LA, LB, LC, LD, LE, and LF do not intersect at one intersection. Note that the perpendicular lines LA, LB, LC, LD, LE, and LF are not limited to this example.

[0091] 2, the plurality of claws 123 are connected to the plurality of protrusions 135. For example, the plurality of claws 123 protrude from the plurality of contact regions 132 along the surface 101a of the metal plate 101. The metal plate 101 is held between the contact surface 121a of the outer wall 121 and the claws 123. Note that the claws 123 may be omitted.

[0092] The resin cover 102 is integrated with the metal plate 101. In this embodiment, the metal plate 101 and the resin cover 102 are integrally formed by insert molding. However, the metal plate 101 and the resin cover 102 may also be integrally formed by other methods such as thermal welding. That is, the resin cover 102 is integrated with the metal plate 101 as it is softened by heating, and is fixed to the metal plate 101.

[0093] The surface 101b of the metal plate 101 and the contact surface 121a of the resin cover 102 are in tight contact (adherence) with each other. Furthermore, the outer peripheral surface 101c of the metal plate 101 and the contact area 132 of the resin cover 102 are in tight contact (adherence) with each other. The metal plate 101 may be attached to the resin cover 102, or may be movable relative to the resin cover 102.

[0094] The heat transfer member 63 is, for example, silicon gel or grease. The heat transfer member 63 is interposed, for example, between the heat sink 73 and the knurling 115 of the metal plate 101. The knurling 115 can prevent the heat transfer member 63 from moving along the surface 101a.

[0095] The heat transfer member 63 thermally connects the heat sink 73 of the circuit board 61 to the metal plate 101. Therefore, the metal plate 101 is thermally connected to the power transistor 72 through the heat transfer member 63 and the heat sink 73.

[0096] The power transistor 72 conducts heat to the metal plate 101 through the heat sink 73 and the heat transfer member 63. The metal plate 101 has a larger heat capacity than the heat sink 73. Therefore, the power transistor 72 is thermally connected to the metal plate 101, so that it can continuously dissipate heat.

[0097] The cover 86 has the metal plate 101, so that it can dissipate heat from the circuit board 61 without being made entirely of metal. That is, the other portion of the cover 86 (the resin cover 102) can be made of resin. Therefore, the resin cover 102 can be attached to the resin base 91 by vibration welding, and thus the accommodation chamber 81 can be sealed simply and watertightly.

[0098] The metal that is the material of the metal plate 101 and the synthetic resin that is the material of the resin cover 102 have different thermal expansion coefficients. In general, the resin cover 102 has a higher thermal expansion coefficient than the metal plate 101. For this reason, for example, when the brake system 10 is in a low-temperature environment or when the cover 86 is released from the mold after insert molding, the resin cover 102 shrinks more than the metal plate 101.

[0099] 3, in the X direction, the metal plate 101 is located between the two contact areas 132A and 132C and between the two contact areas 132B and 132C. When the resin cover 102 contracts, the two contact areas 132A and 132C approach each other in the X direction and press against the outer peripheral surface 101c of the metal plate 101. Furthermore, the two contact areas 132B and 132C approach each other in the X direction and press against the outer peripheral surface 101c of the metal plate 101.

[0100] In the Y direction, the metal plate 101 is located between the two contact areas 132D and 132F and between the two contact areas 132E and 132F. When the resin cover 102 contracts, the two contact areas 132D and 132F approach each other in the Y direction and press against the outer peripheral surface 101c of the metal plate 101. Furthermore, the two contact areas 132E and 132F approach each other in the Y direction and press against the outer peripheral surface 101c of the metal plate 101.

[0101] As described above, the perpendicular lines LA, LB, LC, LD, LE, and LF do not coincide with one another, and the contact regions 132A, 132B, 132C, 132D, 132E, and 132F do not face one another. Furthermore, the perpendicular lines LA, LB, LC, LD, LE, and LF are spaced apart (shifted) from the centers of the linear regions 111A, 111B, 111D, 111F, 111G, and 111H in the first circumferential direction Dc1. Therefore, the metal plate 101 does not support the two approaching contact regions 132 like a support rod, but rotates in the first circumferential direction Dc1. That is, the multiple contact regions 132 push the metal plate 101 to rotate in the first circumferential direction Dc1 as the resin cover 102 contracts.

[0102] The metal plate 101 does not rotate to support the contact region 132, thereby reducing stress in the contact region 132. As the metal plate 101 rotates, the contact region 132 may be partially separated from the outer circumferential surface 101c, or the separated region 132 may be temporarily in contact with the outer circumferential surface 101c.

[0103] Generally, stress concentration is likely to occur at the corners of a structure. However, the contact area 132 of this embodiment is flat and is spaced apart from the corners 112. As described above, the resin cover 102 of this embodiment can reduce stress during shrinkage.

[0104] The two contact areas 132 may face each other. In this case, the protrusion 135 is compressed between the outer peripheral surface 101c of the metal plate 101 and the separation area 131 of the resin cover 102. However, the gap G is adjacent to the protrusion 135. Therefore, for example, the protrusion 135 can elastically expand into the gap G, and the stress when the resin cover 102 contracts can be reduced.

[0105] In the brake system 10 according to the present embodiment described above, the resin cover 102 is integrated with the metal plate 101. The inner peripheral surface 122b of the resin cover 102 surrounds the outer peripheral surface 101c and is partially in contact with the outer peripheral surface 101c and partially spaced apart from the outer peripheral surface 101c. By integrating the resin cover 102 with the metal plate 101, a case 62 capable of efficiently dissipating heat from the circuit board 61 is obtained. Because the resin cover 102 is made of resin, its coefficient of thermal expansion differs from that of the metal plate 101. Therefore, for example, in a low-temperature environment, the resin cover 102 contracts more than the metal plate 101, and the inner peripheral surface 122b presses against the outer peripheral surface 101c. However, because the inner circumferential surface 122b is partially separated from the outer circumferential surface 101c, the metal plate 101 pressed by the inner circumferential surface 122b can move relative to the resin cover 102, or a portion of the resin cover 102 can expand into the gap G between the inner circumferential surface 122b and the outer circumferential surface 101c. Therefore, compared to when the inner circumferential surface 122b contacts the entire outer circumferential surface 101c, the stress caused by contact with the metal plate 101 when the resin cover 102 contracts can be reduced. Furthermore, the resin cover 102 can be easily joined to the resin base 91 by, for example, vibration welding. Therefore, the case 62 can achieve sealing performance with a simple configuration without using a sealing material such as a packing or gasket.

[0106] The inner peripheral surface 122b has multiple contact regions 132. The multiple contact regions 132 are spaced apart from one another in the circumferential direction around the metal plate 101 along the outer peripheral surface 101c and are in contact with the outer peripheral surface 101c. The perpendicular lines LA, LB, LC, LD, LE, and LF of the centers of the multiple contact regions 132 in the circumferential direction do not coincide with the perpendicular lines LA, LB, LC, LD, LE, and LF of the centers of the other multiple contact regions 132 in the circumferential direction. When the resin cover 102 contracts, the multiple contact regions 132 press the metal plate 101 in different directions. That is, the vectors of the forces with which the multiple contact regions 132 press the metal plate 101 are different from one another. Therefore, the metal plate 101 pressed by the multiple contact regions 132 can rotate relative to the resin cover 102 due to the difference in the vectors. Therefore, the case 62 can reduce stress on the resin cover 102.

[0107] The outer peripheral surface 101c has at least one pair of linear regions 111B, 111D extending parallel to each other and positioned opposite each other (on opposite sides of the metal plate 101). The multiple contact regions 132 include contact regions 132B, 132C that contact the linear regions 111B, 111D. Perpendicular lines LB, LD of the circumferential centers of the contact regions 132B, 132C are spaced apart from each other. Therefore, when the resin cover 102 contracts, the two contact regions 132B, 132C can prevent the metal plate 101 from being sandwiched between the two contact regions 132B, 132C. Therefore, the metal plate 101 pressed by the contact regions 132B, 132C can rotate relative to the resin cover 102. Therefore, the case 62 can reduce stress on the resin cover 102.

[0108] In the Y direction in which the linear regions 111B and 111D extend, the contact regions 132B and 132C are at least partially at different positions from each other. Therefore, compared to a case in which one of the contact regions 132B and 132C entirely encompasses the other in the Y direction, the metal plate 101 pressed by the contact regions 132B and 132C is more likely to rotate relative to the resin cover 102. Therefore, the case 62 can reduce stress on the resin cover 102.

[0109] In the Y direction in which the linear regions 111B and 111D extend, the contact regions 132B and 132C are spaced apart from each other. Therefore, compared to when the contact regions 132B and 132C are partially in the same position in the Y direction, the metal plate 101 pressed by the contact regions 132B and 132C is more likely to rotate relative to the resin cover 102. Therefore, the case 62 can reduce stress on the resin cover 102.

[0110] The plurality of contact areas 132 press the metal plate 101 to rotate in the circumferential direction as the resin cover 102 contracts. The rotation of the metal plate 101 pressed by the contact areas 132 allows the case 62 to reduce stress on the resin cover 102.

[0111] The outer peripheral surface 101c has a plurality of linear regions 111 and a plurality of angular portions 112. The linear regions 111 extend linearly in the circumferential direction. One or more angular portions 112 are provided between any two adjacent linear regions 111. The plurality of contact regions 132 are spaced apart from the plurality of angular portions 112. Therefore, compared to a case in which the contact regions 132 contact the angular portions 112, the case 62 can reduce stress on the resin cover 102 and prevent the contact regions 132 from restricting rotation of the metal plate 101.

[0112] The circuit board 61 is housed in a case 62 and is thermally connected to a metal plate 101. The motor 25 receives power from the circuit board 61. A fluid chamber 45 is provided in the pressure regulator 26. The fluid chamber 45 is configured to contain brake fluid. The pressure regulator 26 changes the pressure in the fluid chamber 45 when driven by the motor 25. The circuit board 61 can dissipate heat to the metal plate 101 when a large current flows through it to be supplied to the motor 25. The case 62 can watertightly protect the circuit board 61, through which a large current flows, by attaching a resin cover 102, for example, by vibration welding.

[0113] At least one of the cases described above, for example, includes a metal plate having a first surface facing a heat-generating internal component (inside the case), a second surface located opposite the first surface, and an outer peripheral surface connected to the outer peripheral edge of the first surface and the outer peripheral edge of the second surface, configured to be thermally connected to the component; and a resin casing member integrated with the metal plate, the resin casing member having a contact surface contacting the second surface and an inner peripheral surface surrounding the outer peripheral surface and partially contacting and partially spaced from the outer peripheral surface. Thus, for example, by integrating the resin casing member with the metal plate, a case capable of efficiently dissipating heat from the component is obtained. Because the casing member is made of resin, its coefficient of thermal expansion differs from that of the metal plate. Therefore, for example, in a low-temperature environment, the casing member shrinks more than the metal plate, causing the inner peripheral surface to press against the outer peripheral surface. However, because the inner peripheral surface is partially separated from the outer peripheral surface, the metal plate pressed against the inner peripheral surface can move relative to the casing member, or a portion of the casing member can expand into the gap between the inner and outer peripheral surfaces. Therefore, compared to when the inner peripheral surface is in contact with the entire outer peripheral surface, the stress caused by contact with the metal plate when the casing member contracts can be reduced. Furthermore, the resin casing member can be easily joined to other resin members, for example, by vibration welding. Therefore, the case can achieve sealing performance with a simple configuration without the need for sealing materials such as packings or gaskets.

[0114] In the above case, as an example, the inner peripheral surface has a plurality of contact areas that are spaced apart from each other in the circumferential direction around the metal plate along the outer peripheral surface and that contact the outer peripheral surface, and the perpendicular lines of the centers of the plurality of contact areas in the circumferential direction do not coincide with the perpendicular lines of the centers of the other plurality of contact areas in the circumferential direction. Therefore, as an example, when the casing member contracts, the plurality of contact areas press the metal plate in different directions. That is, the force vectors of the forces pressing the metal plate at the plurality of contact areas are different from each other. Therefore, the metal plate pressed by the plurality of contact areas can rotate relative to the casing member due to the difference in the force vectors. Therefore, the case can reduce stress in the casing member.

[0115] In the above case, as an example, the outer peripheral surface has at least a pair of first parallel regions extending parallel to each other and positioned opposite each other, and the plurality of abutment regions includes a plurality of second parallel regions contacting the at least a pair of first parallel regions, and a perpendicular line of a center of each of the plurality of second parallel regions in the circumferential direction is spaced apart from a perpendicular line of a center of each of the plurality of second parallel regions in the circumferential direction. Therefore, as an example, when the casing member contracts, the two second parallel regions can prevent the metal plate from being sandwiched between the two second parallel regions. Therefore, the metal plate pressed by the second parallel regions can rotate relative to the casing member. Therefore, the case can reduce stress in the casing member.

[0116] In the above case, for example, the second parallel regions are at least partially at different positions from each other in the direction in which the at least one pair of first parallel regions extend. Therefore, for example, compared to when one second parallel region entirely encompasses another second parallel region in the direction in which the first parallel regions extend, the metal plate pressed by the second parallel regions is more likely to rotate relative to the casing member. Therefore, the case can reduce stress on the casing member.

[0117] In the above case, for example, the second parallel regions are spaced apart from one another in the direction in which the at least one pair of first parallel regions extend. Therefore, for example, the metal plate pressed by the second parallel regions is more likely to rotate relative to the casing member than when the second parallel regions are partially in the same position in the direction in which the first parallel regions extend. Therefore, the case can reduce stress on the casing member.

[0118] In the above case, for example, the plurality of contact areas press the metal plate to rotate in the circumferential direction as the casing member contracts, and therefore, for example, the case can reduce stress on the casing member as the metal plate pressed by the contact areas rotates.

[0119] In the above case, as one example, the outer peripheral surface has a plurality of linear regions extending linearly in the circumferential direction, and has a plurality of corners provided between two adjacent ones of the plurality of linear regions, and the plurality of contact regions are spaced apart from the corners. Therefore, as one example, compared to a case in which the contact regions contact the corners, the case can reduce stress on the casing member and can prevent the contact regions from restricting rotation of the metal plate.

[0120] The brake control device according to at least one embodiment described above includes, for example, the case, the component housed in the case and thermally connected to the metal plate, an actuator receiving power from the component, and a pressure regulator having a fluid chamber configured to contain brake fluid and configured to change the pressure in the fluid chamber by being driven by the actuator. Thus, for example, the component can dissipate heat to the metal plate when a large current flows through the actuator. The case includes a resin casing member that is vibration-welded, for example, to provide watertight protection for the component through which the large current flows.

[0121] While the embodiments of the present invention have been described above, the above-described embodiments and modifications are merely examples and are not intended to limit the scope of the invention. The above-described embodiments and modifications can be implemented in various other forms, and various omissions, substitutions, combinations, and modifications can be made without departing from the spirit of the invention. Furthermore, the configurations and shapes of each embodiment and each modification can be partially interchanged. [Explanation of symbols]

[0122] 11...Brake control device, 25...Motor (actuator), 26...Pressure adjustment device, 45...Liquid chamber, 61...Circuit board (component), 62...Case, 101...Metal plate, 101a...Surface (first surface), 101b...Surface (second surface), 101c...Outer surface, 102...Resin cover (casing member), 111, 111A, 111B, 111C, 111D, 111 E,111F,111G,111H,111I...linear area, 112,112A,112B,112C,112D,112E,112F,112G,112H...corner part, 1 21a...Contact surface, 122b...Inner peripheral surface, 132,132A,132B,132C,132D,132E,132F...Abutting area, LA,LB,LC,LD,LE,LF...Perpendicular line.

Claims

1. a metal plate having a first surface facing an internal component that generates heat, a second surface located opposite to the first surface, and an outer peripheral surface connected to the outer peripheral edges of the first surface and the second surface, the metal plate being configured to be thermally connected to the component; a resin casing member that is integrated with the metal plate and that has a contact surface that contacts the second surface and an inner peripheral surface that surrounds the outer peripheral surface and is partially in contact with the outer peripheral surface and partially spaced from the outer peripheral surface; and A case equipped with the above.

2. the inner peripheral surface has a plurality of contact regions that are spaced apart from each other in a circumferential direction around the metal plate along the outer peripheral surface and that contact the outer peripheral surface, a perpendicular line of a center of each of the plurality of contact regions in the circumferential direction does not coincide with a perpendicular line of a center of another of the plurality of contact regions in the circumferential direction; The case of claim 1.

3. The outer peripheral surface has at least a pair of first parallel regions extending parallel to each other and positioned opposite each other, the plurality of contact regions include a plurality of second parallel regions in contact with the at least one pair of first parallel regions; a perpendicular line of a center in the circumferential direction of each of the plurality of second parallel regions is spaced apart from a perpendicular line of a center in the circumferential direction of each of the other second parallel regions; The case of claim 2.

4. the plurality of second parallel regions are at least partially positioned differently from each other in a direction in which the at least one pair of first parallel regions extend; The case of claim 3.

5. the plurality of second parallel regions are spaced apart from each other in a direction in which the at least one pair of first parallel regions extend; The case of claim 4.

6. The plurality of contact areas press the metal plate to rotate in the circumferential direction as the casing member contracts. The case according to any one of claims 2 to 5.

7. The outer circumferential surface has a plurality of linear regions extending linearly in the circumferential direction, and has a plurality of corner portions provided between two adjacent ones of the plurality of linear regions, The plurality of contact regions are spaced apart from the corner portion. The case of claim 2.

8. The case of claim 1; the component housed in the case and thermally connected to the metal plate; an actuator powered by said component; a pressure adjusting device provided with a fluid chamber configured to store brake fluid, and configured to change the pressure of the fluid chamber by being driven by the actuator; A brake control device comprising:

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