Busbar module for rotating electrical machines

Abstract

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

Description

[Technical Field]

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

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

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

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

[0005] [Patent Document 1] Japanese Patent Publication No. 2020-167843 Summary of the Invention [Problem to be solved by the invention]

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

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

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

[0009] According to the present disclosure, it is possible to suppress misalignment of the bus bar. [Brief explanation of the drawings]

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

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

[0012] According to this configuration, first, the first bus bar and the second bus bar are inserted into a first mold, and the cavity of the first mold is filled with molten resin to form a primary molded body consisting of the first bus bar, the second bus bar, and the first retaining portion. In this case, the distance between the bus bars can be made larger than when the cavity of the mold is filled with molten resin while the first bus bar, the second bus bar, and the third bus bar are inserted into the mold. This prevents differences in the flow pressure of the molten resin from occurring. Therefore, misalignment of the first bus bar and the second bus bar is prevented.

[0013] Next, with the primary molded body and the third bus bar inserted into a second molding die, molten resin is filled into the cavity of the second molding die to form a secondary molded body consisting of the primary molded body, the third bus bar, and the second holding portion. At this time, because the third bus bar abuts against the first holding portion, there is no gap between the third bus bar and the first holding portion. This prevents the molten resin from flowing between the third bus bar and the first holding portion. This reduces misalignment of the third bus bar compared to when molten resin is filled with a gap between the third bus bar and the first holding portion.

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

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

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

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

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

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

[0020] According to this configuration, it is possible to further suppress misalignment of the first bus bar, the second bus bar, and the third bus bar. [5] It is preferable that the communicating hole has a first hole formed in the first holding portion and a second hole formed in the second holding portion, and that the second hole is connected to the first hole in the first direction.

[0021] In a configuration in which the second hole formed in the second holding portion communicates with the first hole formed in the first holding portion, the following manufacturing method can be employed. That is, when the second mold is closed, a positioning pin is inserted into a through hole provided in at least one of the first bus bar and the second bus bar that constitute the primary molded body and into the first hole that communicates with the through hole. Therefore, with this configuration, the through hole used in forming the primary molded body and the first hole formed in the first holding portion can be used when forming the secondary molded body.

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

[0023] According to this configuration, the primary molded body, the third bus bar, and the fourth bus bar are inserted into a second molding die, and the cavity of the second molding die is filled with molten resin to form a secondary molded body consisting of the primary molded body, the third bus bar, the fourth bus bar, and the second holding portion. At this time, the fourth bus bar abuts against the first holding portion, so there is no gap between the fourth bus bar and the first holding portion. Therefore, the molten resin does not flow between the fourth bus bar and the first holding portion. This reduces misalignment of the fourth bus bar compared to when molten resin is filled with a gap between the fourth bus bar and the first holding portion.

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

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

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

[0027] [Details of the embodiments of the present disclosure] Specific examples of busbar modules for rotating electric machines according to the present disclosure will be described below with reference to the drawings. In each drawing, for the sake of convenience, some of the configuration may be exaggerated or simplified. The dimensional ratios of the various parts may differ from one drawing to another. The present disclosure is not limited to these examples, but is defined by the claims, and is intended to include all modifications within the meaning and scope of the claims. In this specification, "orthogonal" does not only refer to the case of being strictly orthogonal, but also includes the case of being approximately orthogonal within the scope of the effects of the present embodiment.

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

[0047] The end face of the bent portion 42b on the one side X1 in the first direction is the portion that abuts the tip of the temperature detection portion 81 of the temperature sensor 80. That is, the temperature detection portion 81 of the temperature sensor 80 detects the temperature of the fourth busbar 40.

[0048] The end face of the bent portion 42b on the second direction side Y1 is provided with a recess 42d which is made up of a pair of protrusions protruding in the second direction Y and into which a protrusion (not shown) formed on the temperature detection portion 81 fits.

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

[0086] Furthermore, when the second molding die 120 is closed, positioning pins 124 are inserted into the through holes 34, 44 of the third bus bar 30 and the fourth bus bar 40. In this state, the molten resin R2 is filled into the cavity 123 of the second molding die 120. This further prevents the third bus bar 30 and the fourth bus bar 40 from shifting in position. At this time, a communication hole 70 that communicates with the through holes 34, 44 is formed in the second holding portion 56.

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

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

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

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

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

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

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

[0094] <Example of change> This embodiment can be modified as follows: This embodiment and the following modifications can be combined and implemented within the scope of technical compatibility.

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

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

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

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

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

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

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

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

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

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

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

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

Claims

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

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

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

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

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

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

Images