Manufacturing method of connector receiving unit and electrical component

Abstract

To provide a manufacturing method of a connector receiving unit, a connector receiving unit, and an electrical component capable of improving shape accuracy of communicating holes, manufacturing efficiency, and durability of a manufacturing device.SOLUTION: A stator 31 according to an embodiment of the present disclosure includes a connector mold portion 150 having a base portion 155 and a mounting portion 156, and a receiving terminal 151. The connector mold portion 150 has an inner opening 161a that opens to the inside of a housing 12, and includes a first concave portion 161 that extends in the X direction through the base portion 155, and a bottom opening 162b that opens on the bottom surface of the mounting portion 156, and has a second recess 162 extending the base portion 155 in the Y direction, and a communication hole 160 that communicates the inside and outside of the housing 23 through the first recess 161 and the second recess 162 is formed. The first concave portion 161 penetrates the base portion 155 in the X direction through the outer opening 161b. A back covering portion 104a that closes the outer opening 161b is provided.SELECTED DRAWING: Figure 3

Description

Technical Field

[0001] The present disclosure relates to a method for manufacturing a connector receiving unit and and an electrical component.

Background Art

[0002] For electrical components (such as motors and pumps) mounted on vehicles and the like, a connector receiver is provided in a state of penetrating inside and outside a housing. A connector extending from an external power source is attached to the connector receiver on the outside of the housing. Thereby, a control board provided inside the housing and the external power source are electrically connected via the connector receiver.

[0003] The connector receiver includes a molded body formed of a resin material or the like, and terminals molded on the molded body. A communication hole that communicates inside and outside the housing is formed in the molded body. According to this configuration, the pressure difference inside and outside the housing is alleviated by the gas inside and outside the housing entering and leaving through the communication hole according to the pressure difference between the inside and outside of the housing.

[0004] As a method for forming the above-described communication hole, for example, Patent Document 1 below discloses a method in which, when forming a molded body, injection molding is performed with the tip portions of two rod bodies abutted against each other, and then the two rod bodies are pulled out. According to this method, it is considered that the portions formed by the two rod bodies function as a communication hole by communicating with each other through the abutting portion of the rod bodies.

Prior Art Documents

Patent Documents

[0005]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0006] However, in the above-described prior art, there is still room for improvement in terms of the shape accuracy of the communication holes, manufacturing efficiency, durability of the molding die (rod), etc. Specifically, in the above-described prior art, since it is necessary to abut the tip portions of the rods against each other, high accuracy is required for positioning the rods. Further, since the rods extend cantilevered, there is a possibility that the rods may shift or deform due to injection pressure or the like during molding. If injection molding is performed with the tip portions of the rods shifted, the yield may decrease, such as the communication holes not being formed with a desired cross-sectional area or the communication holes being blocked halfway.

[0007] The present disclosure aims to provide a method for manufacturing a connector receiving unit and an electrical component capable of improving the shape accuracy of communication holes, manufacturing efficiency, and durability of a manufacturing apparatus. and and an electrical component.

Means for Solving the Problems

[0008] In order to solve the above problems, the present disclosure adopts the following aspects. A method for manufacturing a connector receiving unit according to one aspect of the present disclosure is a method for manufacturing a connector receiving unit that is provided in a housing for accommodating an electronic component and to which a connector extending from an external power source is attached, and electrically connects the electronic component and the external power source. The connector receiving unit includes a base portion extending across the inside and outside of the housing, and a bottomed cylindrical mounting portion opening outside the housing, and is integrally formed of a resin material. The connector receiving unit further includes a first end portion exposed inside the housing and connected to the electronic component, and a second end portion exposed inside the mounting portion and connected to the connector, and a terminal provided through the first molded portion. The first molded portion has a first opening opening inside the housing, a first recess extending the base portion in a first direction, a second opening opening on the bottom surface of the mounting portion, and a second recess extending the base portion in a second direction intersecting the first direction. A communication hole is formed to communicate the inside and outside of the housing through the first recess and the second recess. A first molding step of forming the first molded portion is provided by molding with a resin material in a state where a first pin forming the first recess, a second pin forming the second recess, and the terminal are set in a mold. In the first molding step, after injection molding is performed in a state where both end portions of one of the first pin and the second pin are supported by the mold, one end portion of the other pin is supported by the mold, and the other end portion is engaged with the one pin, the first pin and the second pin are pulled out to form the first recess and the second recess. After the first molding step, a closing step is provided of closing one of the openings of the opening formed by the one pin in the first molded portion with a plug portion. A connector receiving unit according to an aspect of the present disclosure includes a base portion extending across the inside and outside of a housing in which an electronic component is housed, and a bottomed cylindrical mounting portion that opens outside the housing and to which a connector extending from an external power source is mounted, and a first molded portion integrally formed of a resin material, and a first end portion that is exposed inside the housing and connected to the electronic component, and a second end portion that is exposed inside the mounting portion and connected to the connector, and a terminal provided through the first molded portion, and the first molded portion has a first opening that opens to the inside of the housing, and a first recess that extends the base portion in a first direction, and a second opening that opens on the bottom surface of the mounting portion, and a second recess that extends the base portion in a second direction intersecting the first direction, and a communication hole that communicates the inside and outside of the housing through the first recess and the second recess is formed, and among the first recess and the second recess, one recess penetrates the base portion in the first direction through a through hole, and includes a plug portion that closes the through hole.

[0009] According to this aspect, since both ends of one pin are supported by the mold, it is easy to ensure the strength of one pin against injection pressure and the like. Thereby, displacement, deformation, etc. of one pin can be suppressed. Along with this, since it becomes easier to engage the other pin with one pin, the first pin and the second pin can be aligned with high precision and easily. Therefore, compared with the configuration in which the tip portions of the rod bodies are butted against each other as in the prior art, the shape accuracy and manufacturing efficiency of the communication hole can be improved, and the durability of the mold can be improved.

[0010] In the manufacturing method of the connector receiving unit of the above aspect, in the closing step, it is preferable to form the plug portion by molding the first molded portion with a resin material. In the connector receiving unit of the above aspect, it is preferable that the connector receiving unit includes the first molded portion and a second molded portion having the plug portion. According to this aspect, compared with a configuration in which a separate member is fitted into the through hole of one recess, one recess can be reliably and easily closed.

[0011] In the method for manufacturing the connector receiving unit according to the above aspect, the dimension of the first pin in the direction orthogonal to the second direction as viewed from the first direction is different from the dimension of the second pin in the direction orthogonal to the first direction as viewed from the second direction. Among the first pin and the second pin, it is preferable that an engaging portion for accommodating the pin with a smaller dimension and restricting the relative movement of the first pin and the second pin is formed on the pin with a larger dimension. According to this aspect, it becomes easier to suppress the displacement of the first pin and the second pin due to the injection pressure or the like during molding. Therefore, the communication hole can be formed with higher precision.

[0012] In the connector receiving unit according to the above aspect, it is preferable that the second molding portion includes a covering portion that covers a resistor inside the housing, and the resistor is electrically connected to the electronic component. Since the connector receiving unit according to the above aspect can form the communication hole with high precision in a desired shape, gas can efficiently enter and exit inside and outside the housing through the communication hole. Therefore, even if a temperature difference occurs between the inside and outside of the housing due to the heat generation of the resistor, the differential pressure between the inside and outside of the housing associated with the temperature difference can be quickly relieved.

[0013] In the connector receiving unit according to the above aspect, it is preferable that the cross-sectional area of the second recess in the direction orthogonal to the second direction gradually increases from the communication portion with the first recess toward the second opening. According to this aspect, the second pin for forming the second recess can be formed in a tapered shape from the tip end toward the base end. Thereby, it can be used as a demolding taper of the second pin, and the mold release property can be improved.

[0014] In the connector receiving unit according to the above aspect, it is preferable that the plug portion is provided at a portion closer to the through hole with respect to the communication portion between the first recess and the second recess in the one recess. According to this aspect, it is possible to suppress the blocking between the first concave portion and the second concave portion, and the inside and outside of the housing can be communicated through the communication hole.

[0015] The electrical component according to the present disclosure includes a housing in which electronic components are housed, and a connector receiving unit according to the above aspect provided in the housing. According to this aspect, since the connector receiving unit according to the above aspect is provided, it is possible to suppress the air pressure fluctuation in the housing and provide an electrical component excellent in durability and operation reliability.

Effects of the Invention

[0016] According to each of the above aspects, it is possible to improve the shape accuracy, manufacturing efficiency, and durability of the manufacturing apparatus of the communication hole.

Brief Description of the Drawings

[0017]

Figure 1

Figure 2

Figure 3

Figure 4

Figure 5

Figure 6

Figure 7

Figure 8

Figure 9

Modes for Carrying Out the Invention

[0018] Next, embodiments of the present disclosure will be described with reference to the drawings. In the present embodiment, a case where the manufacturing method of the connector receiving unit, the connector receiving unit, and the electrical component according to the present disclosure are adopted in an electric water pump (hereinafter referred to as EWP) will be described as an example. In the embodiments and modifications described below, corresponding configurations may be denoted by the same reference numerals and description thereof may be omitted. In the following description, expressions indicating relative or absolute arrangements such as "parallel", "orthogonal", "center", "coaxial", etc. not only strictly represent such arrangements, but also represent states in which they are relatively displaced with tolerances and angles or distances that can obtain the same function.

[0019] (First Embodiment) [EWP1] FIG. 1 is a cross-sectional view of EWP1. The EWP (electrical component) 1 shown in FIG. 1 is mounted on, for example, a vehicle or the like. The EWP1 is provided on at least a cooling water flow path connecting the engine and the radiator, and circulates cooling water between the engine and the radiator. Note that the vehicle may be a hybrid vehicle, a plug-in hybrid vehicle, or the like in addition to a vehicle having only an engine.

[0020] The EWP1 includes a pump unit 11 and a housing 12. The pump unit 11 is, for example, an inner rotor type brushless motor. The pump unit 11 is housed in the housing 12. In the following description, the direction along the axis O of the pump unit 11 (shaft 32 described later) may be simply referred to as the axial direction, the direction intersecting the axis O when viewed from the axial direction may be referred to as the radial direction, and the direction around the axis O may be referred to as the circumferential direction.

[0021] <Housing 12> The housing 12 houses the pump unit 11 and forms a part of the cooling water flow path. The housing 12 includes a pump cover 21 and a flow path block 22. The pump cover 21 covers the pump unit 11 from the first side in the axial direction with respect to the pump unit 11. The pump cover 21 includes a pump housing portion 21a and a mounting flange portion 21b. The pump housing portion 21a is formed in a bottomed cylindrical shape that opens toward the second side in the axial direction. The pump unit 11 is housed inside the pump housing portion 21a. The mounting flange portion 21b projects radially outward from the opening edge (the second side edge in the axial direction) of the pump housing portion 21a.

[0022] The flow path block 22 is superposed on the pump cover 21 from the second side in the axial direction with the pump unit 11 interposed therebetween. The flow path block 22 includes a suction flow path 22a, a discharge flow path 22b, a connection port 22c, and a mounting flange portion 22d.

[0023] The suction flow path 22a is formed in a cylindrical shape coaxially arranged with the axis O. The suction flow path 22a is connected to a portion of the cooling water flow path that is located upstream of EWP1. A spoke 22f is formed on the inner peripheral surface of the suction flow path 22a. The spoke 22f projects radially inward, for example, from positions facing each other in the radial direction on the inner peripheral surface of the suction flow path 22a. A hub 22g is provided at the radially inner end of each spoke 22f. The hub 22g is formed in a cylindrical shape coaxially arranged with the axis O. The hub 22g is supported on the axis O by each spoke 22f inside the suction flow path 22a.

[0024] The discharge flow path 22b surrounds the suction flow path 22a. Specifically, the cross-sectional area of the discharge flow path 22b increases as it extends from one end in the circumferential direction to the other end. The connection port 22c is connected to the other end in the circumferential direction of the discharge flow path 22b. The connection port 22c extends in a direction away from the pump cover 21. The connection port 22c is connected to a portion of the cooling water flow path that is located downstream of EWP1.

[0025] The mounting flange portion 22d projects radially outward from the outer peripheral edge of the discharge flow path 22b. The housing 12 of the present embodiment includes an overlapping portion 12a where the mounting flange portions 21b and 22d overlap in the axial direction, and an offset portion 12b where the mounting flange portions 21b and 22d are offset in the radial direction. The pump cover 21 and the flow path block 22 are assembled in the axial direction by fastening the mounting flange portions 21b and 22d to each other with bolts or the like in the overlapping portion 12a. The offset portion 12b is located in a part of the circumferential direction of the mounting flange portions 21b and 22d. The offset portion 12b has a gap in the radial direction because the mounting flange portion 21b of the pump cover 21 is located radially outside the mounting flange portion 22d of the flow path block 22.

[0026] <Pump unit 11> Figure 2 is a perspective view of the pump unit 11. As shown in FIGS. 1 and 2, the pump unit 11 includes a stator (connector receiving unit) 31, a shaft 32, a rotor 33, and a control board 34.

[0027] As shown in FIG. 1, the stator 31 is assembled to the housing 12. The stator 31 includes a stator body 41, a coil (resistor) 42, a terminal unit 43, a stator mold portion (second molding portion) 44, and a connector receiver 45.

[0028] <Stator body 41> The stator body 41 includes a stator core 51 and an insulator 52. The stator core 51 is formed in a cylindrical shape coaxially arranged with the axis O. The stator core 51 is configured by laminating annular plates formed by punching or the like on an electromagnetic steel sheet in the axial direction. Note that the stator core 51 may be a so-called powder core, a split core, or the like.

[0029] The stator core 51 has a yoke 51a and a plurality of teeth 51b. The yoke 51a is formed in a cylindrical shape arranged coaxially with the axis O. The teeth 51b project radially inward from the inner peripheral surface of the yoke 51a. A plurality of teeth 51b are formed at intervals in the circumferential direction.

[0030] The insulator 52 is attached to the stator core 51 to insulate between the stator core 51 and the coil 42. The insulator 52 surrounds at least the periphery of each tooth 51b. The insulator 52 may be integrally formed with the stator core 51 by insert molding or the like.

[0031] The coil 42 is configured by winding three-phase coil conductors corresponding to the U-phase, V-phase, and W-phase around the teeth 51b for each phase via the insulator 52.

[0032] The terminal unit 43 is disposed on the first axial side with respect to the stator body 41. The terminal unit 43 electrically connects between the coil 42 and the control board 34. The terminal unit 43 includes a terminal block 90 and terminals 91. The terminal block 90 is integrally formed of a resin material or the like. The terminal block 90 is formed in an arc shape centered on the axis O when viewed from the axial direction. The terminal block 90 is assembled from the first axial side with respect to the insulator 52. The terminal block 90 overlaps a part of the stator body 41 when viewed from the axial direction.

[0033] The terminal 91 is formed by, for example, pressing a plate material such as a conductive metal. The terminal 91 is fixed to the terminal block 90 in a state of protruding in the first axial direction. In the present embodiment, three terminals 91 are provided at intervals in the circumferential direction corresponding to the coil conductors of each phase. Each coil conductor of each phase is connected to each terminal 91.

[0034] As shown in FIGS. 1 and 2, the stator mold part 44 is formed by molding with a resin material in a state where the stator main body 41, the coil 42, and the terminal unit 43 are assembled. The stator mold part 44 includes a stator covering part 100, a mounting piece 101, a shaft support wall 102, a spacer part 103, and a connector covering part 104.

[0035] The stator covering part 100 is formed in a cylindrical shape extending coaxially with the axis O. The stator covering part 100 integrally covers the stator main body 41, the coil 42, and the terminal unit 43. A part of the outer peripheral surface of the stator core 51 and a part of the terminal 91 are exposed to the outside from the stator covering part 100. The terminal 91 protrudes from the stator covering part 100 toward the first side in the axial direction. The mounting piece 101 protrudes radially outward from the second side end portion in the axial direction of the stator covering part 100. The mounting piece 101 is sandwiched between the mounting flange parts 21b and 22d of the pump cover 21 and the flow path block 22. The mounting piece 101 is fastened together with the mounting flange parts 21b and 22d at the overlapping part 12a of the housing 12. Note that packing 105 is provided between the mounting piece 101 and the mounting flange part 21b of the pump cover 21 and between the mounting piece 101 and the mounting flange part 22d of the flow path block 22, respectively. Thereby, the space between the pump cover 21 and the flow path block 22 is sealed.

[0036] The shaft support wall 102 closes the first side opening in the axial direction of the stator covering part 100. The spacer part 103 protrudes from the stator covering part 100 toward the first side in the axial direction. A plurality of spacer parts 103 are provided at intervals in the circumferential direction. Note that the description of the connector covering part 104 and the connector receiver 45 will be described later.

[0037] <Shaft 32> The shaft 32 axially penetrates inside the stator main body 41. The first axial end portion of the shaft 32 is integrally molded with the shaft support wall 102. The second axial end portion of the shaft 32 is supported by the hub 22g of the flow path block 22.

[0038] <Rotor 33> The rotor 33 is rotatably supported by the shaft 32 inside the stator core 51. The rotor 33 includes a rotor core 110, a plurality of magnets (not shown), a magnet cover 111, a rotor molding portion 112, and a bush 113.

[0039] The rotor core 110 is formed in a cylindrical shape coaxially arranged with the axis O. The rotor core 110 is configured by laminating annular plates formed by punching or the like on electromagnetic steel sheets in the axial direction.

[0040] The magnets are arranged side by side in the circumferential direction on the outer peripheral surface of the rotor core 110. Each magnet is arranged such that the poles facing the radial direction are opposite poles between adjacent magnets in the circumferential direction. The magnet cover 111 is attached to the rotor core 110 from the outside in the radial direction. The magnet cover 111 covers the magnets from both the outside in the radial direction and both sides in the axial direction. That is, the magnets face the stator core 51 with the magnet cover 111 sandwiched therebetween in the radial direction.

[0041] The rotor molding portion 112 includes a rotor covering portion 112a, a connecting portion 112b, and an impeller portion 112c. The rotor covering portion 112a is formed in a cylindrical shape extending coaxially with the axis O. The rotor covering portion 112a integrally covers the rotor core 110, the magnets, and the magnet cover 111. The outer peripheral portion of the magnet cover 111 is exposed from the rotor covering portion 112a.

[0042] The connecting portion 112b extends radially inward from the rotor covering portion 112a. The connecting portion 112b is formed in a cylindrical shape along the axis O. The second axial end portion of the connecting portion 112b protrudes axially with respect to the rotor covering portion 112a. The impeller portion 112c projects radially outward from the second axial end portion of the connecting portion 112b. The impeller portion 112c is exposed to both the suction passage 22a and the discharge passage 22b.

[0043] The bush 113 is integrally fixed to the inside of the connecting portion 112b and is formed in a cylindrical shape coaxially arranged with the axis O. The shaft 32 passes through the inside of the bush 113. The bush 113 is rotatably supported by the shaft 32. Therefore, the rotor 33 is rotatably supported by the shaft 32 via the bush 113.

[0044] <Control board 34> The control board 34 is arranged on the first axial side with respect to the stator main body 41 in the pump cover 21. The control board 34 is configured by mounting a plurality of electronic components 34b on the front and back surfaces of the board main body 34a. The control board 34 is overlapped with the stator main body 41 with the thickness direction of the board main body 34a along the axial direction. Specifically, the control board 34 is fastened to the spacer portion 103 with screws or the like in a state where the board main body 34a is supported by the spacer portion 103 from the second axial side. A terminal 91 is connected to the board main body 34a. (Partially shown)

[0045] <Connector receptacle 45> The connector receptacle 45 electrically connects the control board 34 and an external power source by removably mounting a connector 180 (see FIG. 3) extending from the external power source (such as a battery). The connector receptacle 45 is molded into the stator mold portion 44 and is integrally formed as the stator 31. Specifically, the connector receptacle 45 is exposed inside and outside the housing 12 by passing through the portion of the mounting piece 101 corresponding to the offset portion 12b.

[0046] Figure 3 is an enlarged cross-sectional view of a portion corresponding to line III-III in Figure 2. Figure 4 is a view taken in the direction of arrow IV in Figure 2. Figure 5 is a cross-sectional view corresponding to line V-V in Figure 3. As shown in Figures 3 to 5, the connector receptacle 45 includes a connector molding portion (first molding portion) 150 and a plurality of receiving-side terminals 151.

[0047] As shown in Figure 3, the connector molding portion 150 is formed by molding a plurality of receiving-side terminals 151 with a resin material. Note that the resin material constituting the connector molding portion 150 is the same as the resin material constituting the stator molding portion 44. However, the resin material constituting the connector molding portion 150 may be different from the resin material constituting the stator molding portion 44.

[0048] The connector molding portion 150 includes a base portion 155 and a mounting portion 156. The base portion 155 extends across the inside and outside of the housing 12 through the gap between the mounting flanges 21b and 22d in the offset portion 12b. The base portion 155 extends from the first side in the axial direction toward the second side as it goes toward the outer side in the radial direction. Specifically, the base portion 155 includes an inner support portion 155a, a connecting portion 155b, and an outer support portion 155c.

[0049] The inner support portion 155a is a portion of the base portion 155 that is exposed inside the housing 12. Specifically, the inner support portion 155a protrudes toward the first side in the axial direction with a part thereof embedded in the portion of the mounting piece 101 that is located inside the housing 12. The connecting portion 155b extends toward the second side in the axial direction as it goes radially outward from the inner support portion 155a. The connecting portion 155b penetrates the mounting piece 101 in the axial direction. Among the outer surfaces of the connecting portion 155b, at least the surface facing the first side in the axial direction is an exposed surface not covered by the stator mold portion 44. The exposed surface of the connecting portion 155b is exposed within the housing 12. Note that a recess 155d that depresses toward the first side in the axial direction is formed at the boundary between the connecting portion 155b and the inner support portion 155a. A part of the mounting piece 101 is embedded in the recess 155d.

[0050] The outer support portion 155c extends radially outward from the end portion on the second side in the axial direction of the connecting portion 155b. The outer support portion 155c gradually increases in dimension in the axial direction as it goes radially outward. The radially outer end portion of the outer support portion 155c is located radially outside the mounting flange portion 21b.

[0051] The mounting portion 156 extends radially outward from the outer support portion 155c. The mounting portion 156 is formed in a bottomed cylindrical shape that opens radially outward. Specifically, the mounting portion 156 includes a bottom wall portion 156a and a peripheral wall portion 156b.

[0052] The bottom wall portion 156a projects to the outer peripheral side with respect to the outer support portion 155c. Note that among the bottom wall portion 156a and the outer support portion 155c, the surface facing the radially outer side constitutes the bottom surface of the mounting portion 156. The peripheral wall portion 156b is formed in a square tube shape that extends radially outward from the outer peripheral edge of the bottom wall portion 156a. The peripheral wall portion 156b surrounds the periphery of the bottom wall portion 156a.

[0053] The receiving terminal 151 is provided to penetrate the connector molding part 150. In the present embodiment, the receiving terminal 151 is formed by subjecting a plate material such as a metal having conductivity to, for example, press working. In the examples of FIGS. 4 and 5, the receiving terminal 151 includes four terminals: a power terminal 151A, a ground terminal 151B, a signal output terminal 151C, and a signal input terminal 151D. In the following description, when it is not necessary to distinguish each receiving terminal 151, they will be collectively described as the receiving terminal 151.

[0054] As shown in FIGS. 1 and 3, the receiving terminal 151 includes a board connection part (first end part) 151a, an embedded part 151b, and a connector connection part (second end part) 151c. The board connection part 151a protrudes from the inner support part 155a toward the first side in the axial direction. The tip part of the board connection part 151a is connected to the board main body 34a. In the example of FIG. 2, the board connection parts 151a of the respective receiving terminals 151 are arranged in a row.

[0055] As shown in FIGS. 1 and 5, the embedded part 151b is the part of the receiving terminal 151 that is embedded in the base part 155. Specifically, the embedded part 151b extends radially outward from the base end part of the board connection part 151a toward the second side in the axial direction, and then further extends radially outward. The embedded part 151b reaches the bottom surface of the mounting part 156.

[0056] As shown in FIG. 4, the connector connection part 151c protrudes from the embedded part 151b toward the inside of the mounting part 156. Inside the mounting part 156, the connector connection part 151c is arranged in two rows with the signal output terminal 151C and the signal input terminal 151D, and the power terminal 151A and the ground terminal 151B arranged side by side. However, the layouts of the board connection part 151a and the connector connection part 151c can be changed as appropriate.

[0057] As shown in FIGS. 3 to 5, a communication hole 160 that communicates the inside and outside of the housing 12 is formed in the connector mold part 150. The communication hole 160 is formed in an L shape or a T shape by a first recess 161 and a second recess 162 that extend perpendicular to each other. In the following description, the extending direction of the first recess 161 may be referred to as the X direction, the extending direction of the second recess 162 may be referred to as the Y direction, and the direction perpendicular to the X direction and the Y direction may be referred to as the Z direction. In the present embodiment, the X direction coincides with the axial direction, and the Y direction coincides with the radial direction.

[0058] The first recess 161 linearly extends in the X direction (axial direction) within the base portion 155. The first recess 161 has a circular cross section perpendicular to the X direction. The first recess 161 is formed with a uniform inner diameter over the entire length in the X direction. However, the first recess 161 may be formed in a tapered shape.

[0059] The first recess 161 penetrates the connecting portion 155b in the X direction. Specifically, the first recess 161 includes an inner opening (first opening, opening portion) 161a that opens on the exposed surface of the connecting portion 155b. The first recess 161 includes an outer opening (through hole, opening portion) 161b that opens on the surface (hereinafter referred to as the back surface) of the connecting portion 155b that faces the side opposite to the exposed surface.

[0060] The second recess 162 linearly extends in the Y direction within the base portion 155. The second recess 162 has a rectangular cross section perpendicular to the Y direction. The second recess 162 is formed in a tapered shape in which the cross-sectional area gradually increases from the -Y side to the +Y side (from the inside to the outside in the radial direction). However, the second recess 162 may be formed with a uniform cross-sectional shape over the entire length in the radial direction.

[0061] The second recess 162 includes a communication opening (communication portion) 162a that opens into the first recess 161 at the -Y side end. The communication opening 162a is connected to a portion closer to the outer opening 161b than the center in the X direction within the first recess 161. The second recess 162 communicates with the inside of the first recess 161 through the communication opening 162a. The second recess 162 has a bottom surface opening (second opening) 162b that opens on the bottom surface of the mounting portion 156 at the +Y side end. The bottom surface opening 162b opens at a portion located between the signal output terminal 151C and the signal input terminal 151D on the bottom surface of the mounting portion 156. That is, the second recess 162 opens toward the +Y side within the mounting portion 156.

[0062] As shown in FIG. 5, the dimension of the communication opening 162a in the Z direction is larger than the dimension (inner diameter) of the first recess 161 in the Z direction. Therefore, the communication opening 162a surrounds the first recess 161 from both sides in the Z direction.

[0063] Here, as shown in FIGS. 3 and 5, in the stator mold portion 44, the above-described connector covering portion 104 is drawn out to the outside of the housing 12 in a state of being integrally continuous with the attachment piece 101. The connector covering portion 104 surrounds the periphery of the base portion 155 outside the housing 12. Specifically, the connector covering portion 104 includes a back surface covering portion (plug portion) 104a and a side surface covering portion 104b.

[0064] The back covering portion 104a covers the portion from the back surface of the connecting portion 155b to the back surface of the outer support portion 155c. The back covering portion 104a closes the outer opening 161b. Therefore, the communication hole 160 opens into the housing 12 through the inner opening 161a and opens into the mounting portion 156 through the bottom opening 162b. Note that a part of the back covering portion 104a may enter the first recess 161 within a range that does not block the communication between the first recess 161 and the second recess 162 through the communication opening 162a. That is, preferably, the portion of the back covering portion 104a that enters the first recess 161 is accommodated between the opening edge of the outer opening 161b and the surface of the inner surface of the second recess 162 located on the +X side, and more preferably, it is accommodated between the opening edge of the outer opening 161b and the surface of the inner surface of the second recess 162 located on the -X side. Thereby, it is possible to suppress the blocking between the first recess 161 and the second recess 162, and the inside and outside of the housing 12 can be communicated through the communication hole 160.

[0065] The side covering portion 104b covers the surfaces facing both sides in the Z direction of the connecting portion 155b and the outer support portion 155c, respectively. The side covering portion 104b bridges the gap between the back covering portion 104a and the mounting piece 101.

[0066] As shown in FIG. 3, a connector 180 is detachably mounted on the mounting portion 156. An insertion port (not shown) is formed on the surface of the connector 180 facing the bottom surface of the mounting portion 156. In a state where the connector 180 is mounted on the mounting portion 156, the receiving terminals 151 are respectively inserted into the insertion port. In the connector 180, connection terminals (not shown) that are respectively connected to the receiving terminals 151 are provided in a state where the receiving terminals 151 are inserted into the insertion port. Each connection terminal is connected to an external power source via a wiring. Note that the wiring is routed to the external power source in a state of being bundled by a sleeve 181 or the like.

[0067] In this embodiment, the connector 180 is preferably fitted to the mounting portion 156 via a sealing ring or the like (not shown). Thereby, the entry of dust or the like into the mounting portion 156 through the space between the inner peripheral surface of the mounting portion 156 and the outer peripheral surface of the connector 180 is restricted. In this case, the inner space of the mounting portion 156 is open to the atmosphere through the insertion port of the connector 180, the sleeve 181, or the like.

[0068] Next, the operation of the EWP1 will be described. In the EWP1 of this embodiment, current is supplied from an external power source to the control board 34 via the connector receptacle 45. The current supplied to the control board 34 is supplied to the coils 42 of each phase via the terminal 91 at a predetermined timing by the operation of the electronic component 34b. When current is supplied to the coil 42, a magnetic field is formed in the stator core 51, and a magnetic attractive force or repulsive force is generated between the magnet of the rotor 33 and the stator core 51. Thereby, the rotor 33 rotates with respect to the stator 31.

[0069] When the rotor 33 rotates, centrifugal force acts on the cooling water flowing into the suction passage 22a by the impeller portion 112c. Due to this centrifugal force, the cooling water is sent out to the downstream side through the discharge passage 22b.

[0070] By the way, depending on the usage situation, usage environment, etc. of the EWP1, a pressure difference may occur between the inside and outside of the housing 12. For example, when the inside of the housing 12 is at a higher pressure than the outside of the housing 12, the gas inside the housing 12 is discharged to the outside of the housing 12 through the communication hole 160. On the other hand, when the inside of the housing 12 is at a lower pressure than the outside of the housing 12, the gas outside the housing 12 flows into the inside of the housing 12 through the communication hole 160. Thus, in the EWP1 of this embodiment, the differential pressure inside and outside the housing 12 is alleviated by the gas inside and outside the housing 12 entering and leaving through the communication hole 160. In particular, in this embodiment, since the communication hole 160 is open to the inner space of the mounting portion 156 through the bottom surface opening 162b, the intrusion of dust and liquid into the housing 12 can be suppressed.

[0071] [Manufacturing Method of the Stator 31] Next, the manufacturing method of the stator 31 described above will be explained. FIG. 6 is a process diagram of the first molding process in the manufacturing method of the stator 31. The stator 31 is manufactured through a first molding process and a second molding process (closing process). In the first molding process, each receiving-side terminal 151 is set in the first mold 200, and the connector receptacle 45 is formed by molding each receiving-side terminal 151. The first mold 200 includes a mold body 201 that forms a cavity 200a, and a molding pin 202 that forms a communication hole 160.

[0072] The mold body 201 includes an upper mold 210, a lower mold 211, and a slide mold 212. The upper mold 210 and the lower mold 211 are parts that form the outer surface of the connector mold part 150, and are provided facing each other in the X direction. For example, the upper mold 210 is provided so as to be movable in the X direction with respect to the lower mold 211. The upper mold 210 holds the substrate connection part 151a of the receiving-side terminal 151 when the first mold 200 is clamped. The slide mold 212 is a part that forms the inner surface of the mounting part 156. The slide mold 212 is provided so as to be movable in the Y direction with respect to the upper mold 210 and the lower mold 211. The slide mold 212 holds the connector connection part 151c of the receiving-side terminal 151 when the first mold 200 is clamped.

[0073] The molding pin 202 includes a first pin 220 (one pin) that forms the first recess 161, and a second pin (the other pin) 221 that forms the second recess 162. The first pin 220 is formed in a columnar shape. The first pin 220 penetrates the cavity 200a in the X direction during mold clamping and is bridged between the upper mold 210 and the lower mold 211. Note that the first pin 220 may be provided so as to be movable integrally with the upper mold 210 and supported by the lower mold 211 during mold clamping, or may be provided integrally with the lower mold 211 and supported by the upper mold 210 during mold clamping.

[0074] The second pin 221 projects cantilevered from the slide type 212 toward the -Y side. The second pin 221 is formed in a prismatic shape that gradually tapers toward the -Y side.

[0075] FIG. 7 is a cross-sectional view corresponding to line VII-VII in FIG. 6. As shown in FIG. 7, in the second pin (the pin with a large dimension) 221, the dimension in the Z direction at the -Y side end is larger than the outer diameter of the first pin (the pin with a small dimension) 220. An engaging portion 221a is formed at the -Y side end (the other end) of the second pin 221. The engaging portion 221a penetrates the second pin 221 in the X direction and is formed in a semicircular shape that is recessed following the outer peripheral surface of the first pin 220 when viewed from the X direction. The outer peripheral surface of the first pin 220 abuts against the inner peripheral surface of the engaging portion 221a during mold clamping. In this state, a part of the first pin 220 is accommodated inside the engaging portion 221a, thereby restricting the movement of the second pin 221 in the Z direction with respect to the first pin 220.

[0076] As shown in FIG. 6, to perform the first molding process using the first molding die 200 described above, the receiving terminal 151 is set in the first molding die 200 and the first molding die 200 is clamped. The receiving terminal 151 is in a state where the embedding portion 151b penetrates the cavity 200a, the substrate connection portion 151a is held by the upper die 210, and the connector connection portion 151c is held by the slide die 212. Also, with the mold clamping, the first pin 220 is supported in a two-sided manner between the upper die 210 and the lower die 211. On the other hand, the second pin 221 is supported in a two-sided manner between the slide die 212 and the first pin 220 by engaging the engaging portion 221a with the first pin 220.

[0077] After the first molding die 200 is clamped, the cavity 200a of the first molding die 200 is filled with a molten resin material. Then, the cavity 200a is filled with the resin material so as to cover the periphery of the receiving terminal 151 and the molding pin 202. By solidifying the resin material, the connector mold portion 150 (see FIG. 3) is injection molded as a primary molded product.

[0078] After the resin material is solidified, the first mold 200 is opened. Specifically, after releasing the holding of the connector connection part 151c, the slide mold 212 is moved to the +Y side. Then, as the second pin 221 moves to the +Y side together with the slide mold 212, the second pin 221 is pulled out from the connector mold part 150. Also, after releasing the holding of the substrate connection part 151a, the upper mold 210 is moved to the +X side. Then, as the first pin 220 moves to the +X side together with the upper mold 210, the first pin 220 is pulled out from the connector mold part 150. As a result, in the connector mold part 150, a first recess 161 is formed in the portion where the first pin 220 has retracted, and a second recess 162 is formed in the portion where the second pin 221 has retracted.

[0079] FIG. 8 is a process diagram for explaining the second molding process. In the following description, mainly the periphery of the connector receptacle 45 in the second molding process will be described. In the second molding process, the stator body 41, the coil 42, the terminal unit 43, and the connector receptacle 45 are set as molded products in the second mold 250 and integrally molded with a resin material.

[0080] The second mold 250 includes an upper mold 251 and a lower mold 252. The upper mold 251 and the lower mold 252 hold, at the time of mold clamping, the portion of the connector mold part 150 from the outer support part 155c to the mounting part 156. The cavity 250a of the second mold 250 has a mounting piece molding part 250b and a covering part molding part 250c. The mounting piece molding part 250b is a space located on the +X side with respect to the outer support part 155c in the second mold 250. The covering part molding part 250c is a space surrounding both the -X side and both sides in the Z direction with respect to the outer support part 155c in the second mold 250. The outer opening 161b of the first recess 161 opens in the covering part molding part 250c.

[0081] To perform the second molding process using the above-described second molding die, each molded product is set in the second molding die 250, and the second molding die 250 is clamped. After clamping the second molding die 250, the cavity 250a of the second molding die 250 is filled with a molten resin material. Then, the cavity 250a is filled with the resin material so as to cover the periphery of each molded product. At this time, since the resin material is also filled in the attachment piece forming portion 250b and the covering portion forming portion 250c, the periphery of the base portion 155 is covered with the resin material. That is, the outer opening 161b of the first recess 161 is blocked by the resin material. Thereafter, by solidifying the resin material, the stator mold portion 44 is injection molded.

[0082] After the resin material is solidified, by opening the second molding die 250, the stator 31 is formed as a secondary molded product. That is, the stator 31 is formed in a state where the outer opening 161b of the first recess 161 is blocked by the stator mold portion 44.

[0083] As described above, in the present embodiment, in the first molding process, both end portions of the first pin 220 are supported by the first molding die 200 (the upper die 210 and the lower die 211), one end portion of the second pin 221 is supported by the first molding die 200 (the slide die 212), and the other end portion is supported by the first pin 220. According to this configuration, since both end portions of the first pin 220 are supported by the first molding die 200, it is easy to ensure the strength of the first pin 220 against injection pressure and the like. Thereby, displacement, deformation, etc. of the first pin 220 can be suppressed. Along with this, since it becomes easy to bring the second pin 221 into contact with the first pin 220, the first pin 220 and the second pin 221 can be aligned with high precision and easily. Therefore, compared with the configuration in which the tip portions of the rod bodies are butted against each other as in the prior art, the shape accuracy and manufacturing efficiency of the communication hole 160 can be improved, and the durability of the first molding die 200 can be improved.

[0084] In the present embodiment, in the second molding process, the connector mold portion 150 is molded by the stator mold portion 44 so as to block the outer opening 161b of the first recess 161. According to this configuration, compared with a configuration in which a separate member is fitted into the outer opening 161b of the first recess 161, etc., the outer opening 161b can be surely and easily closed.

[0085] In the present embodiment, the stator mold part 44 is configured to include a stator covering part 100 that covers the coil 42 within the housing 12. According to this configuration, as described above, the connector receiver 45 of the present embodiment can form the communication hole 160 into a desired shape with high precision. Therefore, gas can efficiently flow in and out between the inside and outside of the housing 12 through the communication hole 160. Therefore, even if a temperature difference occurs between the inside and outside of the housing 12 due to the heat generation of the coil 42, the differential pressure between the inside and outside of the housing 12 associated with the temperature difference can be quickly alleviated.

[0086] In the present embodiment, the cross-sectional area of the second recess 162 is configured to gradually increase from the communication opening 162a toward the bottom opening 162b. According to this configuration, the second pin 221 for forming the second recess 162 can be formed in a tapered shape from the tip end portion toward the base end portion. Thereby, it can be used as a demolding taper of the second pin 221, and the mold release property can be improved.

[0087] In the present embodiment, the second pin 221 is configured to have an engaging portion 221a that houses the first pin 220 and restricts the movement of the first pin 220 with respect to the second pin 221. According to this configuration, it becomes easier to suppress the displacement of the first pin 220 and the second pin 221 due to the injection pressure or the like during molding. Therefore, the communication hole 160 can be formed with higher precision.

[0088] Since the EWP1 of the present embodiment includes the stator 31 of the present embodiment described above, it is possible to provide an EWP1 that suppresses air pressure fluctuations within the housing 12 and is excellent in durability and operation reliability.

[0089] (Second Embodiment) FIG. 9 is an explanatory view of a first molding process according to the second embodiment. The second embodiment is different from the first embodiment in that an engaging portion is formed on the first pin 220. In the molding pin 202 shown in FIG. 9, the first pin 220 is formed in a prismatic shape extending in the X direction. The first pin 220 penetrates the cavity 200a with one surface of the outer peripheral surface facing the +Y side. An engaging portion 220a that opens toward the +Y side is formed on the first pin 220. The engaging portion 220a is formed, for example, in a circular shape when viewed from the Y direction.

[0090] The second pin 221 is formed in a columnar shape extending in the Y direction. The outer diameter of the second pin (the pin with a smaller size) 221 is smaller than the dimension of the first pin (the pin with a larger size) 220 in the Z direction. The -Y side end of the second pin 221 is engaged in the engaging portion 220a during mold clamping. Thereby, the second pin 221 is supported by the first pin 220.

[0091] Even with such a configuration, in the first molding process, displacement, deformation, etc. of the first pin 220 can be suppressed. Along with this, it becomes easier to bring the second pin 221 into contact with the first pin 220, so the first pin 220 and the second pin 221 can be aligned with high precision and easily.

[0092] (Other Modification Examples) As described above, the preferred embodiments of the present disclosure have been described, but the present disclosure is not limited to these embodiments. Additions, omissions, substitutions, and other changes to the configuration are possible without departing from the spirit of the present disclosure. The present disclosure is not limited by the above description and is limited only by the appended claims. For example, in the above-described embodiment, the EWP1 was described as an electrical component in which the electronic component 34b is housed in the housing 12, but the present disclosure is not limited to this configuration. The configuration according to the present disclosure can also be adopted for electrical components other than the EWP1. Examples of the electrical component may include a motor other than the EWP1, a vehicle ECU (Electronic Control Unit), or the like. In this case, the electronic component (resistor) itself constituting the electrical component may be molded in the second molded body.

[0093] In the above-described embodiment, the configuration in which the coil 42 and the like are molded in the second molded body has been described, but the present disclosure is not limited to this configuration. The second molded body does not have to mold other than the connector receptacle 45 as long as it closes at least the outer opening 161b. In the above-described embodiment, the configuration in which a part (the back surface covering portion 104a) of the stator mold portion 44 is used as the plug portion has been described, but the present disclosure is not limited to this configuration. The plug portion may be formed as a separate member from the mold portion. In this case, the plug portion may close the outer opening 161b by fitting or adhering to the outer opening 161b.

[0094] In the above-described embodiment, the configuration in which the first pin 220 and the second pin 221 are supported via the engaging portion formed on one of the pins has been described, but the present disclosure is not limited to this configuration. For example, the second pin 221 may only contact (engage) the outer peripheral surface of the first pin 220. In the above-described embodiment, the configuration in which the first pin 220 is supported in a two-sided manner by the first mold 200 and the tip of the second pin 221 contacts (engages) the first pin 220 has been described, but the present disclosure is not limited to this configuration. A configuration in which the second pin 221 is supported in a two-sided manner by the first mold 200 and the tip of the first pin 220 engages with the second pin 221 may also be adopted. In this case, among the openings formed by the second pin 221, the through-hole located on the side opposite to the bottom opening 162b is closed by the plug portion. In the above-described embodiment, the first recess 161 and the second recess 162 are described by taking the configuration in which they are orthogonal to each other as an example, but the configuration is not limited thereto. The first recess 161 and the second recess 162 may intersect at an angle other than a right angle as long as they are configured to communicate the inside and outside of the housing 12.

[0095] In the above-described embodiment, the case where one communication hole 160 is formed has been described, but the number and layout of the communication holes 160 can be changed as appropriate. In the above-described embodiment, the configuration in which the first recess 161 and the second recess 162 communicate with each other to form the communication hole 160 has been described, but the configuration is not limited thereto. In addition to the first recess 161 and the second recess 162, other recesses may be communicated.

[0096] In addition, within the scope not departing from the gist of the present disclosure, it is possible to appropriately replace the components in the above-described embodiment with well-known components, and the above-described modified examples may be combined as appropriate.

Description of Reference Numerals

[0097] 1: EWP (Electrical Component) 12: Housing 31: Stator (Connector Receiving Unit) 34b: Electronic Component 42: Coil (Resistor) 44: Stator Molded Part (Second Molding Part) 45: Connector Receiver 100: Stator Coating Part (Coating Part) 104a: Back Surface Coating Part (Plug Part) 150: Connector Molded Part (First Molding Part) 151: Receiving Side Terminal (Terminal) 151a: Substrate Connection Part (First End) 151c: Connector Connection Part (Second End) 155: Base Part 156: Mounting Part 160: Communication Hole 161: First Recess 161a: Inner Opening (First Opening, Opening Part) 161b: Outer opening (one opening, through-hole) 162: Second recess 162a: Communication opening (communication part) 162b: Bottom opening (second opening) 180: Connector 200: First mold (mold) 220: First pin (one pin, the other pin, pin with small dimension, pin with large dimension) 220a: Engagement part 221: Second pin (the other pin, one pin, pin with large dimension, pin with small dimension) 221a: Engagement part

Claims

1. A method for manufacturing a connector receiving unit that is provided in a housing for accommodating electronic components and is electrically connected to the electronic components and an external power source by attaching a connector extending from the external power source, comprising: The connector receiving unit includes: a first molded part integrally formed of a resin material, having a base part extending across the inside and outside of the housing and a bottomed cylindrical mounting part opening outside the housing; a terminal provided through the first molded part, having a first end exposed inside the housing and connected to the electronic component and a second end exposed inside the mounting part and connected to the connector; The first molded part has a first opening opening inside the housing, a first recess extending the base part in a first direction, a second opening opening on the bottom surface of the mounting part, and a second recess extending the base part in a second direction intersecting the first direction, and a communication hole is formed to communicate the inside and outside of the housing through the first recess and the second recess; A first molding step of forming the first molded part by molding with a resin material in a state where a first pin forming the first recess, a second pin forming the second recess, and the terminal are set in a mold; In the first molding step, after injection molding is performed in a state where both ends of one of the first pin and the second pin are supported by the mold, one end of the other pin is supported by the mold, and the other end is engaged with the one pin, the first pin and the second pin are pulled out to form the first recess and the second recess; A method for manufacturing a connector receiving unit, comprising a closing step of closing one of the openings of the opening formed by the one pin in the first molded part with a plug part after the first molding step.

2. The method for manufacturing a connector receiving unit according to claim 1, wherein in the closing step, the plug part is formed by molding the first molded part with a resin material.

3. The dimension of the first pin in the direction orthogonal to the second direction as viewed from the first direction is different from the dimension of the second pin in the direction orthogonal to the first direction as viewed from the second direction. In the manufacturing method of the connector receiving unit according to claim 1 or claim 2, among the first pin and the second pin, an engaging portion that accommodates the pin with a smaller dimension and restricts relative movement between the first pin and the second pin is formed on the pin with a larger dimension.

4. A housing in which an electronic component is housed, A first molded part integrally formed of a resin material, having a base portion extending across the inside and outside of the housing, and a bottomed cylindrical mounting portion that opens outside the housing and to which a connector extending from an external power source is mounted. A terminal having a first end exposed in the housing and connected to the electronic component, and a second end exposed in the mounting portion and connected to the connector, and provided through the first molded part. The first molded part has a first opening that opens to the inside of the housing, a first recess that extends the base portion in a first direction, and a second opening that opens on the bottom surface of the mounting portion, and a second recess that extends the base portion in a second direction intersecting the first direction. A communication hole that communicates the inside and outside of the housing through the first recess and the second recess is formed. Among the first recess and the second recess, one of the recesses penetrates the base portion in the first direction through a through hole. It includes a plug portion that closes the through hole. The first molded part is molded, and a second molded part having the plug portion is provided. The second molded part includes a coating portion that coats a resistor in the housing. The resistor is an electrical component electrically connected to the electronic component.

5. The electrical component according to claim 4, wherein the cross-sectional area orthogonal to the second direction in the second recess gradually increases from the communication portion with the first recess toward the second opening.

6. The electrical component according to claim 4 or claim 5, wherein the plug portion is provided at a portion closer to the through hole than the communication portion between the first recess and the second recess in the one recess.

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