Terminal module for rotating electric machinery

Abstract

To provide a terminal module capable of reducing vibration propagated from a rotary electric machine by a simple configuration.SOLUTION: A terminal module 100 electrically connects between a stator configuring a rotary electric machine and a terminal base 80. The terminal module 100 comprises a plurality of bus bars 10, 20, 30, and 40, and a holding member 50 covering the plurality of bus bars 10, 20, 30, and 40. Each of the plurality of bus bars 10, 20, and 30 has: a long extension part 13, 23, 33 located between a first end part 11, 21, 31 and a second end part 12, 22, 32 and extended in a first direction X; and an intermediate part located between the extension parts 13, 23, 33 and the second end parts 12, 22, 32. The extension parts 13, 23, and 33 are configured so as to be able to reduce vibration propagated from the stator toward the terminal base 80.SELECTED DRAWING: Figure 1

Description

[Technical Field]

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

[0002] Patent Document 1 discloses a bus bar that electrically connects an electric motor and a power supply circuit that supplies power to the electric motor. This bus bar has a terminal portion on one end side attached to a terminal block of the power supply circuit, a terminal portion on the other end side attached to a stator terminal of the electric motor, and a main body portion joined to both terminal portions and electrically connecting the terminal portions to each other.

[0003] The main body portion is formed of a flexible conductor. According to such a bus bar, vibration transmitted from the electric motor is absorbed by the flexible main body portion. [Prior Art Documents] [Patent Documents]

[0004] [Patent Document 1] Japanese Unexamined Patent Publication No. 2021-9781 [Summary of the Invention] [Problem to be Solved by the Invention]

[0005] By the way, in a terminal module for a rotating electric machine provided with such a bus bar, since the main body portion and the terminal portion of the bus bar are provided as separate components, the number of components increases, and labor for joining the main body portion and the terminal portion is required.

[0006] An object of the present disclosure is to provide a terminal module for a rotating electric machine that can reduce vibration transmitted from the rotating electric machine with a simple configuration. [Means for Solving the Problem]

[0007] The terminal module for a rotating electric machine according to the present disclosure is a terminal module for a rotating electric machine that electrically connects a stator constituting a rotating electric machine with a terminal block, and comprises a plurality of busbars integrally formed from a metal plate material, and a retaining member formed from an electrically insulating resin that covers the plurality of busbars and is interposed between the plurality of busbars, wherein when the axial direction and circumferential direction of the rotating electric machine are defined as a first direction and a second direction, respectively, the plurality of busbars have a first end electrically connected to the terminal block, a second end electrically connected to the coil of the stator, an elongated extension portion located between the first end and the second end and extending in the first direction, and an intermediate portion located between the extension portion and the second end and covered by the retaining member, and includes a first busbar, a second busbar, and a third busbar arranged side by side in the second direction, wherein the extension portion is configured to reduce vibrations transmitted from the stator toward the terminal block. [Effects of the Invention]

[0008] According to this disclosure, vibrations transmitted from a rotating electric machine can be reduced with a simple configuration. [Brief explanation of the drawing]

[0009] [Figure 1] Figure 1 is a perspective view showing one embodiment of a terminal module for a rotating electric machine, specifically a terminal module mounted on a terminal block. [Figure 2] Figure 2 is a plan view showing the terminal module from Figure 1 attached to the stator. [Figure 3] Figure 3 is a bottom view showing the terminal module of Figure 1. [Figure 4] Figure 4 is a perspective view showing the first and second busbars. [Figure 5] Figure 5 is a perspective view showing the third busbar. [Figure 6] Figure 6 is a perspective view showing the fourth busbar. [Figure 7] Figure 7 is a perspective view showing the primary mold. [Figure 8]Figure 8 is a bottom view showing the primary mold body of Figure 7. [Figure 9] Figure 9 is a diagram showing the molding process of the primary mold body of Figure 7, and is a cross-sectional view showing the state in which molten resin has been filled into the cavity of the first mold. [Figure 10] Figure 10 is a perspective view showing the primary mold, the third busbar, and the fourth busbar separated. [Figure 11] Figure 11 is a plan view showing the primary mold body with the third and fourth busbars attached. [Figure 12] Figure 12 is a bottom view showing the primary mold body with the third and fourth busbars attached. [Figure 13] Figure 13 is a diagram showing the molding process of the secondary mold, and is a cross-sectional view showing the state in which molten resin has been filled into the cavity of the second mold. [Figure 14] Figure 14 is a cross-sectional view along the 14X-14X line in Figure 2. [Modes for carrying out the invention]

[0010] [Description of Embodiments in this Disclosure] First, the embodiments of this disclosure will be listed and described. The terminal module for rotating electric machines of this disclosure is [1] A terminal module for a rotary electric machine that electrically connects a stator constituting the rotary electric machine and a terminal block, comprising: a plurality of busbars integrally formed from a metal plate material; and a holding member formed of an electrically insulating resin, covering the plurality of busbars and interposed between the plurality of busbars, wherein when the axial direction and the circumferential direction of the rotary electric machine are defined as a first direction and a second direction respectively, each of the plurality of busbars includes: a first end electrically connected to the terminal block, a second end electrically connected to the coil of the stator, an elongated extension part located between the first end and the second end and extending in the first direction, and an intermediate part located between the extension part and the second end and covered by the holding member, the plurality of busbars include a first busbar, a second busbar, and a third busbar arranged side by side in the second direction, and the extension part is configured to be capable of reducing vibration transmitted from the stator toward the terminal block.

[0011] According to this configuration, the holding member integrally holds the first busbar, the second busbar, and the third busbar, and is interposed between the respective busbars. Therefore, the busbars are electrically insulated from each other by the holding member.

[0012] Further, according to the above configuration, since the first busbar, the second busbar, and the third busbar each have the elongated extension part extending in the first direction, flexibility is improved. As a result, vibration transmitted from the stator toward the terminal block is easily absorbed by the extension part. Therefore, vibration transmitted from the rotary electric machine can be reduced with a simple configuration.

[0013] [2] It is preferable to further comprise a connecting member formed of an electrically insulating resin and integrally covering the extension part of each of the first busbar, the second busbar, and the third busbar. In each bus bar, as the length of the extending portions in the first direction increases, the extending portions are more likely to be relatively displaced from each other. In this regard, according to the above configuration, the extending portions of the respective bus bars are integrally connected to each other by the connecting member. This can suppress displacement of the extending portions of the respective bus bars from their regular positions. Therefore, workability when connecting the first end portion of each bus bar to the terminal block can be improved.

[0014] [3] It is preferable that the connecting member has a plurality of holes through which each of the extending portions penetrates in the first direction, and at least one of the extending portions among the first bus bar, the second bus bar, and the third bus bar, and the connecting member include a restricting portion that restricts relative movement of the connecting member with respect to the extending portion in the first direction by means of a concavo-convex relationship.

[0015] According to this configuration, relative movement of the connecting member with respect to the extending portions of the respective bus bars in the first direction is restricted by the restricting portion. Therefore, positioning of the connecting member with respect to each bus bar can be easily performed.

[0016] [4] It is preferable that the restricting portion includes a convex portion protruding toward the inner circumferential surface of the hole from at least one of the extending portions among the first bus bar, the second bus bar, and the third bus bar, and a concave portion formed on the inner circumferential surface.

[0017] According to this configuration, the tendency of the connecting member to move relatively with respect to the extending portions of the respective bus bars in the first direction is restricted by the concavo-convex relationship between the convex portion protruding from the extending portion and the concave portion formed on the inner circumferential surface of the hole of the connecting member. Therefore, the restricting portion can be embodied with a simple configuration.

[0018] [5] It is preferable that the convex portion is provided at a position closer to the first end portion than a central portion of the extending portion in the first direction. In the extended portion, the closer it is to the first end, the more likely it is to deviate from its normal position. In this regard, according to the above configuration, the protrusion is positioned closer to the first end than to the central part in the first direction of the extended portion. Therefore, the connecting member is positioned closer to the first end than to the central part. This effectively suppresses the deviation of the extended portion of each busbar from its normal position. Consequently, the workability when connecting the first end of each busbar to the terminal block can be further improved.

[0019] [6] Preferably, the intermediate portion of each of the first busbar, the second busbar, and the third busbar has an elongated main body portion extending in the second direction and a leg portion that bends from the main body portion and extends in the first direction opposite to the extended portion and is connected to the second end.

[0020] In conventional terminal modules, the legs connected to the second end extend in a third direction, i.e., the radial direction of the rotating electric machine, making it difficult to miniaturize the rotating electric machine in that third direction. In this respect, according to the above configuration, the legs of the intermediate section bend from the main body and extend in the first direction away from the first end. Therefore, compared to conventional busbars in which the legs extend from the main body in a third direction, the length of the intermediate section in the third direction can be reduced. Consequently, the size of the terminal module can be reduced in the third direction.

[0021] [7] Preferably, the retaining member has a first retaining portion that covers the first busbar and the second busbar and is interposed between the first busbar and the second busbar, and a second retaining portion that covers the first retaining portion and the third busbar.

[0022] When a holding member integrally holds the first, second, and third busbars, if the cross-sectional area of ​​the gaps between the busbars is small, molten resin will have difficulty flowing through these gaps in the cavity formed by the mold for forming the holding member and each busbar. As a result, if the cross-sectional area of ​​the flow path on the opposite side of the gap between the busbars is larger than the cross-sectional area of ​​the gap, a difference will occur 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. Therefore, this pressure difference can cause problems such as the busbars being prone to shifting from their normal positions.

[0023] In this regard, according to the above configuration, first, with the first busbar and the second busbar inserted into the first mold, a primary mold body consisting of the first busbar, the second busbar, and the first retaining part is formed by filling the cavity of the first mold with molten resin. Next, with the primary mold body and the third busbar inserted into the second mold, a secondary mold body consisting of the primary mold body, the third busbar, and the second retaining part is formed by filling the cavity of the second mold with molten resin.

[0024] Therefore, compared to the case where molten resin is filled into the cavity of the mold with the first, second, and third busbars inserted into the mold, the distance between the first and second busbars can be increased. This suppresses differences in the flow pressure of the molten resin. Consequently, displacement of the first and second busbars can be suppressed.

[0025] [8] When the radial direction of the rotating electric machine is the third direction, the third busbar preferably has a bent portion between the extended portion and the intermediate portion of the third busbar, and the bent portion has a portion that bends from the extended portion and extends inward in the third direction.

[0026] With this configuration, the height of the extended portion in the first direction, i.e., the position of the first end in the first direction, and the position of the extended portion in the third direction are adjusted simply by changing the length of the bent portion in the third direction. This allows the dimensions of the extended portion of the third busbar to be adjusted after the primary mold body has been formed. Therefore, the third busbar is less likely to shift position compared to when molten resin is filled into the cavity of the mold with the first, second, and third busbars inserted into the mold. Thus, the shifting of the third busbar can be suppressed.

[0027] [9] The first retaining portion has a groove into which a portion of the third busbar fits, the groove comprising a bottom surface against which the portion abuts, and a pair of sides rising from both sides of the bottom surface in a second direction, wherein the pair of sides preferably sandwich the portion in the second direction.

[0028] According to this configuration, when forming the secondary mold body, the relative movement of the third busbar relative to the primary mold body in the second direction due to the flow pressure of the molten resin is restricted by the interference between the pair of sides of the groove and a part of the third busbar fitted into the groove. Therefore, displacement of the third busbar can be further suppressed.

[0029]

[10] The plurality of busbars include a fourth busbar that is electrically connected to the neutral wire of the coil, and the first retaining portion has a base portion having a first contact surface against which one end surface of the third busbar in the first direction abuts, and a second contact surface located on the opposite side of the first contact surface in the first direction and against which the fourth busbar abuts, and the second retaining portion preferably covers the fourth busbar.

[0030] According to this configuration, a secondary mold body consisting of the primary mold body, the third busbar, the fourth busbar, and the second retaining part is formed by filling the cavity of the second mold with molten resin while the primary mold body, the third busbar, and the fourth busbar are inserted into the second mold. At this time, since the fourth busbar is in contact with the first retaining part, there is no gap between the fourth busbar and the first retaining part. Therefore, displacement of the fourth busbar can be suppressed compared to when molten resin is filled with a gap between the fourth busbar and the first retaining part.

[0031] [Details of the embodiments of this disclosure] Specific examples of terminal modules for rotating electric machines of this disclosure are described below with reference to the drawings. In each drawing, some parts of the configuration may be exaggerated or simplified for ease of explanation. Also, the dimensional ratios of each part may differ in each drawing. This disclosure is not limited to these examples, but is indicated by the claims, and all modifications within the meaning and scope of equivalence to the claims are intended. In this specification, "orthogonal" includes not only strictly orthogonal but also generally orthogonal to the extent that the effects of this embodiment are achieved.

[0032] <Overall configuration of terminal module 100> As shown in Figures 1 and 2, the terminal module 100 electrically connects a rotating electric machine 90, such as a motor generator in a hybrid vehicle or electric vehicle, to a terminal block 80.

[0033] The rotating electric machine 90 is driven by, for example, a multi-phase AC (in this embodiment, a three-phase AC consisting of U-phase, V-phase, and W-phase). The rotating electric machine 90 consists of a cylindrical stator 91 having a stator core 92 with multiple slots (not shown) and coils 93 inserted into the slots, and a rotor (not shown) positioned radially inward of the stator 91. The coils 93 consist of three phase coils corresponding to each of the three phases (U phase, V phase, and W phase).

[0034] The terminal block 80 has a first terminal 81, a second terminal 82, and a third terminal 83, and a housing 84 that accommodates the terminals 81, 82, and 83. One end 81a, 82a, and 83a of each terminal 81, 82, and 83 in the direction of extension are electrically connected to the terminal module 100. The other end of each terminal 81, 82, and 83 in the direction of extension are electrically connected to an inverter (not shown) that converts DC current from a battery to AC current (in this embodiment, 3-phase AC current). In this embodiment, the first terminal 81 corresponds to the U phase, the second terminal 82 corresponds to the V phase, and the third terminal 83 corresponds to the W phase.

[0035] The terminal module 100 is located at one end of the stator 91 in the axial direction. The terminal module 100 includes a first busbar 10, a second busbar 20, a third busbar 30, and a fourth busbar 40 that are electrically connected to the coil 93, and a retaining member 50 that covers each of the busbars 10, 20, 30, and 40.

[0036] Furthermore, the terminal module 100 has a connecting member 70 that integrally covers each of the busbars 10, 20, and 30. The following describes in detail each component of the terminal module 100.

[0037] In the following, the axial direction, circumferential direction, and radial direction of the rotating electric machine 90 will be described as the first direction X, the second direction Y, and the third direction Z, respectively. Furthermore, in the first direction X, the side on which the terminal module 100 is positioned relative to the stator 91 will be described as the first direction side X1, and the opposite side will be described as the first direction other side X2. Furthermore, in the third direction Z, the side of the rotating electric machine 90 along its central axis will be described as the third direction inner Z1, and the opposite side will be described as the third direction outer Z2.

[0038] <1st bus bar 10, 2nd bus bar 20> As shown in Figure 4, the first busbar 10 and the second busbar 20 are each integrally formed from a conductive metal plate.

[0039] The first bus bar 10 and the second bus bar 20 are spaced apart from each other in the second direction Y. In the following explanation, in the second direction Y, the side of the second busbar 20 relative to the first busbar 10 will be referred to as the first side of the second direction Y1, and the opposite side will be referred to as the other side of the second direction Y2.

[0040] The first busbar 10 has a first end 11 that is electrically connected to the first terminal 81 of the terminal block 80, and a second end 12 that is electrically connected to the coil 93 of the stator 91. Furthermore, the first busbar 10 has an extended portion 13 located between the first end 11 and the second end 12, and an intermediate portion 14 located between the extended portion 13 and the second end 12.

[0041] The first end portion 11 and the extended portion 13 are, as a whole, flat plates that extend in a first direction X and in a direction perpendicular to both the first direction X and the third direction Z. As shown in Figures 1 and 4, the first end portion 11 is provided with a fastening hole 11a (see Figure 4) that penetrates in the third direction Z and through which a bolt (not shown) is inserted, and a nut 11b (see Figure 1). The nut 11b is fixed to the end face of the first end portion 11 on the inner side Z1 in the third direction.

[0042] The first end portion 11 and the first terminal 81 of the terminal block 80 (see Figure 1) are fixed to each other by inserting a bolt (not shown) through a fastening hole (not shown) formed in one end 81a and a fastening hole 11a, and then screwing the bolt into a nut 11b.

[0043] As shown in Figure 4, the extended portion 13 is elongated and extends continuously from the first end portion 11 in the first direction X. The extended portion 13 has a protrusion 13a. The protrusion 13a protrudes from the end face of the extended portion 13 on one side Y1 in the second direction. The protrusion 13a is located closer to the first end portion 11 than to the central portion of the extended portion 13 in the first direction X.

[0044] The intermediate section 14 has an intermediate section body 14a that bends from the extended section 13 and extends in a second direction Y, and a leg section 14b that bends from the intermediate section body 14a and extends in a first direction X, and is connected to the second end section 12.

[0045] The intermediate body 14a is a flat plate that extends in both the second direction Y and the third direction Z. The leg portion 14b is connected to the end face of the intermediate body 14a on the third inner side Z1. The leg portion 14b extends from the intermediate body 14a in the first direction X to the opposite side from the extending portion 13, i.e., to the other side X2 in the first direction.

[0046] The second end portion 12 is bent from the end portion X2 on the other side in the first direction of the leg portion 14b and protrudes as a whole toward the inside Z1 in the third direction. The second end portion 12 has a flat plate portion 12a located on the leg portion 14b side in the third direction Z, and a rod-shaped projection portion 12b located on the tip side.

[0047] The flat plate portion 12a is provided with a through hole 15 that penetrates in the first direction X. The projection 12b is elongated and extends in the third direction Z. The projection 12b protrudes from the end face of the flat plate portion 12a on the inner side Z1 in the third direction. In this embodiment, the projection 12b is the portion connected to the power line (not shown) of the coil corresponding to the U phase of the coil 93.

[0048] As shown in Figure 4, the second busbar 20 has a first end 21 that is electrically connected to the third terminal 83 of the terminal block 80, and a second end 22 that is electrically connected to the coil 93 of the stator 91.

[0049] Furthermore, the second busbar 20 has an extended portion 23 located between the first end portion 21 and the second end portion 22, and an intermediate portion 24 located between the extended portion 23 and the second end portion 22. The first end portion 21 and the extended portion 23 are, as a whole, flat plates that extend in a first direction X and in a direction perpendicular to both the first direction X and the third direction Z.

[0050] As shown in Figures 1 and 4, the first end portion 21 is provided with a fastening hole 21a (see Figure 4) that penetrates in the third direction Z and through which a bolt (not shown) is inserted, and a nut 21b (see Figure 1). The nut 21b is fixed to the end face of the first end portion 21 on the inner side Z1 in the third direction.

[0051] The first end portion 21 and the third terminal 83 of the terminal block 80 (see Figure 1) are fixed to each other by inserting a bolt (not shown) through a fastening hole (not shown) formed in one end 83a and a fastening hole 21a, and then screwing the bolt into a nut 21b.

[0052] As shown in Figure 4, the extended portion 23 is elongated and extends continuously from the first end portion 21 in the first direction X. The extended portion 23 has a protrusion 23a. The protrusion 23a protrudes from the end face of the extended portion 23 on one side Y1 in the second direction. The protrusion 23a is located closer to the first end portion 21 than to the central portion of the extended portion 23 in the first direction X.

[0053] The intermediate portion 24 has an intermediate portion body 24a that bends from the extended portion 23 and extends in a second direction Y, and a leg portion 24b that bends from the intermediate portion body 24a and extends in a first direction X, and is connected to the second end portion 22.

[0054] The intermediate body 24a is a flat plate that extends in both the second direction Y and the third direction Z. The leg portion 24b is connected to the end face of the intermediate body 24a on the third inner side Z1. The leg portion 24b extends from the intermediate body 24a in the first direction X to the opposite side from the extending portion 23, i.e., to the other side X2 in the first direction.

[0055] The second end portion 22 is bent from the end portion X2 on the other side in the first direction of the leg portion 24b and protrudes as a whole toward the inside Z1 in the third direction. The second end portion 22 has a flat plate portion 22a located on the leg portion 24b side in the third direction Z, and a rod-shaped projection portion 22b located on the tip side.

[0056] The flat plate portion 22a is provided with a through hole 25 that penetrates in the first direction X. The projection 22b is elongated and extends in the third direction Z. The projection 22b protrudes from the end face of the flat plate portion 22a on the inner side Z1 in the third direction. In this embodiment, the projection 22b is the portion connected to the power line (not shown) of the coil corresponding to the W phase of the coil 93.

[0057] <3rd Bus Bar 30> As shown in Figure 5, the third busbar 30 is integrally formed from a conductive metal plate. The third busbar 30 has a first end 31 that is electrically connected to the second terminal 82 of the terminal block 80, and a second end 32 that is electrically connected to the coil 93 of the stator 91.

[0058] Furthermore, the third busbar 30 has an extended portion 33 located between the first end portion 31 and the second end portion 32, an intermediate portion 34 located between the extended portion 33 and the second end portion 32, and a bent portion 35 located between the extended portion 33 and the intermediate portion 34.

[0059] The first end portion 31 and the extended portion 33 are, as a whole, flat plates that extend in a first direction X and in a direction perpendicular to both the first direction X and the third direction Z. As shown in Figures 1 and 5, the first end portion 31 is provided with a fastening hole 31a (see Figure 5) that penetrates in the third direction Z and through which a bolt (not shown) is inserted, and a nut 31b (see Figure 1). The nut 31b is fixed to the end face of the first end portion 31 on the inner side Z1 in the third direction.

[0060] The first end portion 31 and the second terminal 82 of the terminal block 80 (see Figure 1) are fixed to each other by inserting a bolt (not shown) through a fastening hole (not shown) formed in one end 82a and a fastening hole 31a, and then screwing the bolt into a nut 31b.

[0061] As shown in Figure 5, the extended portion 33 is elongated and extends continuously from the first end portion 31 in the first direction X. The extended portion 33 has a protrusion 33a. The protrusion 33a protrudes from the end face of the extended portion 33 on one side Y1 in the second direction. The protrusion 33a is located closer to the first end portion 31 than to the central portion of the extended portion 33 in the first direction X.

[0062] The bent portion 35 has a first portion 35a that bends from the extended portion 33 and extends in a third direction Z, and a second portion 35b that bends from the first portion 35a and extends in a first direction X, and is connected to the intermediate portion 34.

[0063] The first portion 35a bends from the extending portion 33 and extends inward in the third direction Z1. The second part 35b is bent from the tip of the first part 35a and extends to the other side X2 in the first direction.

[0064] The intermediate section 34 has an elongated intermediate section body 34a extending in the second direction Y, and a leg portion 34b that bends from the intermediate section body 34a and extends in the first direction X, and is connected to the second end portion 32.

[0065] The intermediate section body 34a is a flat plate shape that extends in both the first direction X and the second direction Y. The second portion 35b of the bent section 35 is connected to the center of the end face of the intermediate section body 34a on one side X1 in the first direction, in the second direction Y.

[0066] The leg portion 34b bends from the end of the intermediate body portion 34a on one side Y1 in the second direction and extends in the first direction X to the opposite side from the extending portion 33, i.e., to the other side X2 in the first direction. The second end portion 32 is bent from the end portion X2 on the other side in the first direction of the leg portion 34b and protrudes as a whole toward the inside Z1 in the third direction.

[0067] The second end portion 32 has a flat plate portion 32a located on the leg portion 34b side in the third direction Z, and a rod-shaped projection portion 32b located on the tip side. The flat plate portion 32a is provided with a through hole 36 that penetrates in the first direction X.

[0068] The projection 32b is elongated and extends in the third direction Z. The projection 32b protrudes from the end face of the flat plate portion 32a in the third direction Z1. In this embodiment, the projection 32b is the portion connected to the power line (not shown) of the coil corresponding to the V phase of the coil 93.

[0069] <4th Bus Bar 40> As shown in Figure 6, the fourth busbar 40 is integrally formed from a conductive metal plate. The fourth busbar 40 forms the neutral point of the coil 93 and has third ends 43A, 43B, and 43C connected to the neutral wire (not shown) of the coil 93, and an intermediate section 40A to which each of the third ends 43A, 43B, and 43C is connected.

[0070] The intermediate section 40A extends as a whole in the second direction Y. The intermediate section 40A has a first intermediate section 41 located between the third end 43A and the third end 43B, and a second intermediate section 42 located between the third end 43B and the third end 43C.

[0071] The first intermediate portion 41 is a flat plate that extends in both the second direction Y and the third direction Z. The second intermediate section 42 rises from the end of the first intermediate section 41 on one side Y1 in the second direction to the first side X1 and extends toward the second side Y1.

[0072] The third ends 43A, 43B, and 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 ends 43A, 43B, and 43C are arranged at equal intervals from each other in the second direction Y.

[0073] The third ends 43A and 43B project outward from the end face of the first intermediate portion 41 in the third direction inward Z1. The third end portions 43A and 43B have a flat plate portion 43a located on the side of the first intermediate portion 41 in the third direction Z, and a rod-shaped projection portion 43b located on the tip side.

[0074] The flat plate portion 43a is provided with a through hole 44 that penetrates in the first direction X. The projection 43b is elongated and extends in the third direction Z. The projection 43b protrudes from the end face of the flat plate portion 43a in the third direction Z1.

[0075] The third end portion 43C is bent from the end face X2 on the other side in the first direction of the second intermediate portion 42 and protrudes inward towards the third direction Z1 as a whole. The third end portion 43C has an inclined portion 43c located on the second intermediate portion 42 side in the third direction Z, and a rod-shaped projection 43d located on the tip side.

[0076] The inclined portion 43c is inclined toward one side Y1 in the second direction as it moves away from the second intermediate portion 42 in the third direction Z. The projection 43d is elongated and extends in the third direction Z. The projection 43d protrudes from the end face of the inclined portion 43c in the third direction Z1.

[0077] In this embodiment, the protrusions 43b and 43d are the parts connected to the neutral wire (not shown) of the coil 93. <Basic configuration of the holding member 50> As shown in Figures 1 to 8, the retaining member 50 is made of an electrically insulating resin material and covers the busbars 10, 20, 30, and 40.

[0078] The retaining member 50 has a first retaining portion 51 that covers the first busbar 10 and the second busbar 20 and is interposed between the two busbars 10 and 20, and a second retaining portion 57 that covers the first retaining portion 51, the third busbar 30, and the fourth busbar 40.

[0079] Furthermore, the retaining member 50 has a plurality of communication holes 60 that communicate with the through holes 15, 25, 36, and 44 in the first direction X. The communication holes 60 include first holes 61a and 61b formed in the first retaining portion 51 and second holes 62 formed in the second retaining portion 57.

[0080] The following describes in detail each component of the retaining member 50. <First holding part 51> As shown in Figures 4, 7, and 8, the first retaining portion 51 has a base portion 51A, a first surrounding portion 52 that covers the extended portions 13 and 23, and a second surrounding portion 53 that covers the second end portions 12 and 22.

[0081] The base portion 51A extends in the second direction Y and covers the entire intermediate portions 14 and 24 of the first busbar 10 and the second busbar 20. As shown in Figure 11, the base portion 51A has a first contact surface C1 to which the end face of the other side X2 in the first direction of the intermediate portion 34 of the third busbar 30 abuts. The first contact surface C1 extends along the intermediate portion 34. The first contact surface C1 is provided on the end face 51a of the base portion 51A on one side X1 in the first direction (the front side in the direction perpendicular to the plane of the paper in Figure 11).

[0082] As shown in Figures 8 and 12, in the first direction X, a fitting recess 54A is formed on the end face 51b of the base portion 51A opposite to the end face 51a, into which the intermediate portion 40A of the fourth busbar 40 fits. The bottom surface of the fitting recess 54A constitutes a second contact surface C2 into which the end face of one side X1 in the first direction of the intermediate portion 40A abuts.

[0083] As shown in Figures 4 and 7, the first surrounding portion 52 protrudes from the end face 51a of the base portion 51A in one direction X1 and partially covers the extended portions 13 and 23. As shown in Figures 7, 10, and 11, the first surrounding portion 52 has a first groove 55 on the end face of one side X1 in the first direction into which the bent portion 35 of the third busbar 30 fits. The first groove 55 is located in the center of the first surrounding portion 52 in the second direction Y.

[0084] The first groove 55 has a bottom surface 55a that abuts against the first portion 35a of the bent portion 35 of the third busbar 30, and a pair of side surfaces 55b that rise from both sides of the bottom surface 55a in the second direction Y to one side X1 in the first direction.

[0085] As shown in Figure 11, the pair of side surfaces 55b sandwich the first portion 35a of the bent portion 35 in the second direction Y. The distance between the pair of side surfaces 55b is slightly greater than the width of the first portion 35a.

[0086] As shown in Figures 4, 7, and 8, the second surrounding portion 53 protrudes inward in the third direction Z1 from the base portion 51A and covers the flat plate portions 12a and 22a of the second ends 12 and 22. As shown in Figures 8 and 12, a fitting recess 54B is formed on the end face 53b of the second surrounding portion 53 on the other side X2 in the first direction, which is connected to the fitting recess 54A and into which the third ends 43A and 43B of the fourth busbar 40 are fitted. The bottom surface of the fitting recess 54B constitutes a third contact surface C3 into which the end faces of the first side X1 of the third ends 43A and 43B abut.

[0087] As shown in Figures 4, 7, and 8, the second surrounding portion 53 is provided with two first holes 61a and 61b. The first holes 61a and 61b are arranged alternately from the other side Y2 in the second direction toward the one side Y1 in the second direction. Each first hole 61a communicates with the through hole 15 of the first busbar 10 and the through hole 25 of the second busbar 20 in the first direction X.

[0088] As shown in Figures 7 and 8, the end face of the first retaining portion 51 in the third direction inward Z1 is provided with a second groove 56 into which the intermediate portion 34 and a part of the second end portion 32 of the third busbar 30 fit. The second groove 56 extends in the first direction X from the base portion 51A to the second surrounding portion 53. The second groove 56 has a bottom surface 56a into which the leg portion 34b of the intermediate portion 34 of the third busbar 30 abuts, and a pair of side surfaces 56b that rise from both sides of the bottom surface 56a in the second direction Y inward Z1.

[0089] As shown in Figures 11 and 12, the pair of side surfaces 56b sandwich the leg portion 34b of the intermediate portion 34 and the flat plate portion 32a of the second end portion 32 in the second direction Y. The distance between the pair of side surfaces 56b is slightly greater than the width of the leg portion 34b and the flat plate portion 32a.

[0090] <Configuration of the second holding part 57> As shown in Figures 1 and 3, the second retaining portion 57 has a base portion 58 extending in the second direction Y and a third surrounding portion 59 covering a part of the third busbar 30.

[0091] As shown in Figures 1 to 8, the base portion 58 covers the flat plate portion 32a of the second end portion 32 of the third busbar 30. The base portion 58 also covers the end face X2 on the other side in the first direction of the first retaining portion 51, and covers the intermediate portion 40A of the fourth busbar 40 and a part of the third end portions 43A, 43B, and 43C. More specifically, the base portion 58 covers the flat plate portion 43a of the third end portions 43A and 43B and the inclined portion 43c of the third end portion 43C.

[0092] As shown in Figure 3, five second holes 62 are formed in the base portion 58. As shown in Figures 1 and 3 to 8, each second hole 62 communicates in the first direction X with the through hole 15 of the first busbar 10, the through hole 25 of the second busbar 20, the through hole 36 of the third busbar 30, and the two through holes 44 of the fourth busbar 40. The second holes 62 that communicate with the through holes 15 and 25 also communicate with the first hole 61a in the first direction X.

[0093] As shown in Figures 1 and 5, the third surrounding portion 59 protrudes from the base portion 58 in one direction X1. The third surrounding portion 59 covers a part of the second portion 35b of the bent portion 35 of the third busbar 30 and the intermediate portion 34. In addition, the second groove 56 of the first retaining portion 51 is filled by the third surrounding portion 59 and the base portion 58 (see Figure 1).

[0094] <Connecting member 70> As shown in Figures 1, 2, and 14, the connecting member 70 is made of an electrically insulating resin material and integrally covers the respective extended portions 13, 23, and 33 of the busbars 10, 20, and 30.

[0095] The connecting member 70 has a first portion 71 that covers the first busbar 10, a second portion 72 that covers the third busbar 30, and a third portion 73 that covers the second busbar 20. The second part 72 is located between the first part 71 and the third part 73 in the third direction Z.

[0096] The first part 71, the second part 72, and the third part 73 are aligned in the second direction Y, and adjacent parts in the second direction Y are connected to each other. The first part 71, the second part 72, and the third part 73 each have holes 71a, 72a, and 73a through which the extending portions 13, 33, and 23, respectively, pass in the first direction X.

[0097] As shown in Figure 14, a recess 71c is formed on the inner circumferential surface 71b of hole 71a at a position corresponding to a protrusion 13a projecting toward the inner circumferential surface 71b. Similarly, recesses (not shown) are formed on the inner circumferential surfaces (not shown) of holes 72a and 73a at positions corresponding to protrusions 33a and 23a projecting toward the inner circumferential surface. The recesses of the second part 72 and the third part 73 have the same configuration as the recess 71c of the first part 71. Therefore, in the following description, only the recess 71c of the first part 71 will be explained, and the descriptions of the recesses of the second part 72 and the third part 73 will be omitted.

[0098] The protrusion 13a is fitted into the recess 71c. The recess 71c and the protrusion 13a are configured to engage with each other, thereby restricting the relative movement of the first portion 71, i.e., the connecting member 70, with respect to the extending portion 13 in the first direction X.

[0099] The convex portion 13a and the concave portion 71c correspond to the restrictive portion described in [Description of Embodiments of this Disclosure]. <Method for manufacturing terminal module 100> Next, the manufacturing method of the terminal module 100 will be described with reference to Figures 9 to 13. Figure 9 corresponds to the cross-sectional view along the line 9X-9X in Figure 8, and Figure 13 corresponds to the cross-sectional view along the line 13X-13X in Figure 11.

[0100] First, as shown in Figure 9, a positioning pin 114 is inserted through the through hole 25 of the second busbar 20. Also, although not shown in the figure, a positioning pin 114 is inserted through the through hole 15 of the first busbar 10. In this state, the upper mold 111 and lower mold 112 of the first molding die 110 are clamped together. This positions the first busbar 10 and the second busbar 20, which are inserted into the first molding die 110, relative to the cavity 113.

[0101] Next, molten resin R1 is filled into the cavity 113 of the first mold 110. This forms a primary mold body 101 consisting of a first busbar 10, a second busbar 20, and a first retaining part 51. At this time, a first hole 61a is formed in the first retaining part 51, which communicates with the through holes 15 and 25, respectively. In addition, a first hole 61b is formed in the first retaining part 51 by a pin (not shown).

[0102] Next, as shown in Figure 10, the third busbar 30 and the fourth busbar 40 are attached to the primary mold body 101. As shown in Figures 10 and 11, the first portion 35a of the bent portion 35 is fitted into the first groove 55, and the leg portion 34b of the intermediate portion 34 and the flat plate portion 32a of the second end portion 32 are fitted into the second groove 56. This positions the third busbar 30 relative to the primary mold body 101.

[0103] At this time, the end face X2 on the other side in the first direction of the intermediate body 34a of the third busbar 30 is in contact with the end face 51a (first contact surface C1) of the base portion 51A (see Figure 13). Also, the first portion 35a of the bent portion 35 is in contact with the bottom surface 55a of the first groove portion 55 (see Figure 1). In addition, the end face Z2 on the third outer side of the leg portion 34b is in contact with the bottom surface 56a.

[0104] Here, the length of the bent portion 35 in the third direction Z may be adjusted. Specifically, the length of the first portion 35a of the bent portion 35 in the third direction Z is changed. This adjusts the height of the extended portion 33 in the first direction X, i.e., the position of the first end portion 31 in the first direction X, and the position of the extended portion 33 in the third direction Z.

[0105] Furthermore, the position of the first end portion 31 in the first direction X is adjusted to be the same as the positions of the first end portions 11 and 21 in the first direction X (see Figure 1). Also, the position of the extension portion 33 in the third direction Z is adjusted to be located between the extension portion 13 of the first busbar 10 and the extension portion 23 of the second busbar 20 in the third direction Z (see Figure 11). As a result, the extension portions 13, 23, and 33, and consequently the first end portions 11, 21, and 31, are aligned in the second direction Y.

[0106] As shown in Figures 10 and 12, the fourth busbar 40 is attached to the fitting recesses 54A and 54B of the first retaining portion 51. This positions the fourth busbar 40 in the correct mounting position relative to the primary mold body 101. At this time, the end face of one side X1 in the first direction of the fourth busbar 40 is in contact with the second contact surface C2 of the base portion 51A and the third contact surface C3 of the second surrounding portion 53.

[0107] As shown in Figure 13, when the third busbar 30 and the fourth busbar 40 are attached to the primary mold body 101, the third busbar 30, the second busbar 20, and the fourth busbar 40 are spaced apart from each other in the first direction X. Similarly, the third busbar 30, the first busbar 10 (not shown), and the fourth busbar 40 are spaced apart from each other in the first direction X.

[0108] Next, a positioning pin 124 is inserted through the through hole 25 of the second busbar 20. Although not shown in the figure, positioning pins 124 are also inserted through the through holes 36 and 44 of the third busbar 30 and the fourth busbar 40. In this state, the upper mold 121 and lower mold 122 of the second mold 120 are clamped together as shown in Figure 13. This positions the primary mold body 101, the third busbar 30, and the fourth busbar 40 inserted into the second mold 120 relative to the cavity 123.

[0109] Next, molten resin R2 is filled into the cavity 123 of the second mold 120. This forms a secondary mold 102 consisting of a primary mold body 101, a third busbar 30, a fourth busbar 40, and a second holding part 57. At this time, as shown in Figure 13, the second holding part 57 has a first hole 61a communicating with the through hole 15 and the through hole 25, a second hole 62 communicating with the first hole 61b communicating with the through hole 36, and the two through holes 44.

[0110] At this time, the second end 12, the third end 43A, the second end 22, the third end 43B, the second end 32, and the third end 43C are arranged sequentially from the other side Y2 in the second direction toward the one side Y1 in the second direction, and are also arranged at equal intervals from each other in the second direction Y (see Figures 1 to 3).

[0111] Next, the effects and advantages of this embodiment will be described. (1) The first busbar 10 is located between the first end 11 and the second end 12 and has an elongated extension 13 that extends in the first direction X. The second busbar 20 is located between the first end 21 and the second end 22 and has an elongated extension 23 that extends in the first direction X. The third busbar 30 is located between the first end 31 and the second end 32 and has an elongated extension 33 that extends in the first direction X. The extensions 13, 23, and 33 are configured to reduce vibrations transmitted from the stator 91 to the terminal block 80.

[0112] In this configuration, the retaining member 50 integrally holds the first busbar 10, the second busbar 20, and the third busbar 30, and is interposed between each of the busbars 10, 20, and 30. Therefore, the retaining member 50 electrically insulates the busbars 10, 20, and 30 from each other.

[0113] Furthermore, with the above configuration, the first busbar 10, the second busbar 20, and the third busbar 30 have elongated extensions 13, 23, and 33 that extend in the first direction X, thereby increasing their flexibility. As a result, vibrations transmitted from the stator 91 to the terminal block 80 are more easily absorbed by the extensions 13, 23, and 33. Therefore, vibrations transmitted from the rotating electric machine 90 can be reduced with a simple configuration.

[0114] (2) It is equipped with a connecting member 70 made of an electrically insulating resin that integrally covers the extended portions 13, 23, and 33 of the first busbar 10, the second busbar 20, and the third busbar 30, respectively. In each busbar 10, 20, and 30, the longer the length of the extended portion 13, 23, and 33 in the first direction X, the more likely the extended portions 13, 23, and 33 are to be misaligned relative to each other. In this respect, with the above configuration, the extended portions 13, 23, and 33 of each busbar 10, 20, and 30 are integrally connected by the connecting member 70. This makes it possible to suppress misalignment of the extended portions 13, 23, and 33 of each busbar 10, 20, and 30 from their normal positions. Therefore, the workability when connecting the first ends 11, 21, and 31 of each busbar 10, 20, and 30 to the terminal block 80 can be improved.

[0115] (3) The connecting member 70 has a plurality of holes 71a, 72a, 73a through which the extended portions 13, 23, 33 penetrate in the first direction X. The extended portion 13 of the first busbar 10 has a convex portion 13a as a restricting portion. The connecting member 70 has a concave portion 71c as a restricting portion.

[0116] With this configuration, the relative movement of the connecting member 70 in the first direction X with respect to the extended portions 13, 23, and 33 of each busbar 10, 20, and 30 is restricted by the restricting portion. Therefore, the positioning of the connecting member 70 with respect to each busbar 10, 20, and 30 can be easily performed.

[0117] (4) The restricting portion has a protrusion 13a that projects from the extended portion 13 of the first busbar 10 toward the inner circumferential surface 71b of the hole 71a, and a recess 71c formed on the inner circumferential surface 71b. With this configuration, the movement of the connecting member 70 relative to the extended portions 13, 23, and 33 of each busbar 10, 20, and 30 in the first direction X is restricted by the relationship between the convex portion 13a protruding from the extended portion 13 and the concave portion 71c formed on the inner circumferential surface 71b of the hole 71a of the connecting member 70. Therefore, the restricting portion can be realized with a simple configuration.

[0118] (5) The protrusions 13a (23a, 33a) are located in the extended portion 13 (23, 33) that are closer to the first end portion 11 (21, 31) than to the central portion in the first direction X. In the extended portions 13, 23, and 33, the closer they are to the first ends 11, 21, and 31, the more likely they are to deviate from their normal position. In this regard, according to the above configuration, the protrusion 13a is provided in a position closer to the first end 11 than to the central part in the first direction X of the extended portion 13. Therefore, the connecting member 70 is positioned closer to the first end 11 than to the central part. This effectively suppresses the deviation of the extended portions 13, 23, and 33 of each busbar 10, 20, and 30 from their normal position. Consequently, the workability when connecting the first ends 11, 21, and 31 of each busbar to the terminal block 80 can be further improved.

[0119] (6) The intermediate sections 14, 24, 34 of the first bus bar 10, the second bus bar 20, and the third bus bar 30 each have elongated intermediate section bodies 14a, 24a, 34a extending in the second direction Y, and leg sections 14b, 24b, 34b that bend from the intermediate section bodies 14a, 24a, 34a and extend in the first direction X on the opposite side from the extended sections 13, 23, 33, and are connected to the second end sections 12, 22, 32.

[0120] In conventional terminal modules, the legs connected to the second ends 12, 22, and 32 extend in the third direction Z, making it difficult to miniaturize the rotating electric machine 90 in the third direction Z. In this respect, according to the above configuration, the legs 14b, 24b, and 34b of the intermediate sections 14, 24, and 34 bend from the intermediate section bodies 14a, 24a, and 34a and extend in the first direction X on the opposite side from the first ends 11, 21, and 31. Therefore, compared to conventional busbars in which the legs 14b, 24b, and 34b extend from the intermediate section bodies 14a, 24a, and 34a in the third direction Z, the length of the intermediate sections 14, 24, and 34 in the third direction Z can be reduced. Consequently, the size of the terminal module 100 can be reduced in the third direction Z.

[0121] (7) The retaining member 50 has a first retaining portion 51 that covers the first busbar 10 and the second busbar 20 and is interposed between the first busbar 10 and the second busbar 20, and a second retaining portion 57 that covers the first retaining portion 51 and the third busbar 30.

[0122] When the holding member 50 integrally holds the first busbar 10, the second busbar 20, and the third busbar 30, if the cross-sectional area of ​​the gaps between the busbars 10, 20, and 30 is small, the molten resin will have difficulty flowing through these gaps in the cavity formed by the mold for forming the holding member 50 and each of the busbars 10, 20, and 30. As a result, if the cross-sectional area of ​​the flow path on the opposite side of the gap between the busbars 10, 20, and 30 is larger than the cross-sectional area of ​​the gap, a difference will occur 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. Therefore, this pressure difference can cause problems such as the busbars 10, 20, and 30 being prone to shifting from their correct positions.

[0123] In this regard, according to the above configuration, first, with the first busbar 10 and the second busbar 20 inserted into the first mold 110, molten resin R1 is filled into the cavity 113 of the first mold 110 to form a primary mold body 101 consisting of the first busbar 10, the second busbar 20, and the first retaining part 51. Next, with the primary mold body 101 and the third busbar 30 inserted into the second mold 120, molten resin R2 is filled into the cavity 123 of the second mold 120 to form a secondary mold body 102 consisting of the primary mold body 101, the third busbar 30, and the second retaining part 57.

[0124] Therefore, when the first busbar 10, the second busbar 20, and the third busbar 30 are inserted into the mold, the distance between the first busbar 10 and the second busbar 20 can be increased compared to when molten resin is filled into the cavity of the mold. This suppresses differences in the flow pressure of the molten resin R1. Consequently, displacement of the first busbar 10 and the second busbar 20 can be suppressed.

[0125] (8) The third bus bar 30 has a bent portion 35 between the extended portion 33 and the intermediate portion 34 of the third bus bar 30. The bent portion 35 has a first portion 35a that bends from the extended portion 33 and extends inward in the third direction Z1.

[0126] With this configuration, the height of the extension portion 33 in the first direction X, i.e., the position of the first end portion 31 in the first direction X, and the position of the extension portion 33 in the third direction Z are adjusted simply by changing the length of the bent portion 35 in the third direction Z. This allows the dimensions of the extension portion 33 of the third busbar 30 to be adjusted after the primary mold body 101 has been formed. Therefore, the third busbar 30 is less likely to shift position compared to when molten resin is filled into the cavity of the mold with the first busbar 10, second busbar 20, and third busbar 30 inserted into the mold. Thus, the shifting of the third busbar 30 can be suppressed.

[0127] (9) The first retaining portion 51 has a first groove 55 into which the first portion 35a of the bent portion 35 of the third busbar 30 fits. The first groove 55 has a bottom surface 55a into which the first portion 35a abuts, and a pair of side surfaces 55b rising from both sides of the bottom surface 55a in the second direction Y. The pair of side surfaces 55b sandwich the first portion 35a in the second direction Y. The first retaining portion 51 also has a second groove 56 into which the leg portion 34b and the flat plate portion 32a of the third busbar 30 fit. The second groove 56 has a bottom surface 56a into which the leg portion 34b abuts, and a pair of side surfaces 56b rising from both sides of the bottom surface 56a in the second direction Y. The pair of side surfaces 56b sandwich the leg portion 34b and the flat plate portion 32a in the second direction Y.

[0128] With this configuration, when forming the secondary mold body 102, the relative movement of the third busbar 30 relative to the primary mold body 101 in the second direction Y due to the flow pressure of the molten resin R2 is restricted by interference between the pair of side surfaces 55b of the first groove 55 and the first portion 35a of the third busbar 30 fitted into the first groove 55. Similarly, the relative movement of the third busbar 30 relative to the primary mold body 101 in the second direction Y is restricted by interference between the pair of side surfaces 56b of the second groove 56 and the leg portion 34b and flat portion 32a of the third busbar 30 fitted into the second groove 56. Therefore, displacement of the third busbar 30 can be further suppressed.

[0129] (10) The multiple busbars include a fourth busbar 40 which is electrically connected to the neutral wire of the coil 93. The first retaining portion 51 includes a base portion 51A which has a first contact surface C1 against which one end surface of the third busbar 30 in a first direction X abuts, and a second contact surface C2 and a third contact surface C3 which are located on the opposite side of the first contact surface C1 in the first direction X and against which the fourth busbar 40 abuts. The second retaining portion 57 covers the fourth busbar 40.

[0130] According to this configuration, with the primary mold body 101, the third busbar 30, and the fourth busbar 40 inserted into the second mold 120, molten resin R2 is filled into the cavity 123 of the second mold 120, thereby forming a secondary mold body 102 consisting of the primary mold body 101, the third busbar 30, the fourth busbar 40, and the second holding part 57. At this time, since the fourth busbar 40 is in contact with the first holding part 51, there is no gap between the fourth busbar 40 and the first holding part 51. Therefore, compared to the case where molten resin R2 is filled with a gap between the fourth busbar 40 and the first holding part 51, displacement of the fourth busbar 40 can be suppressed.

[0131] <Example of changes> This embodiment can be implemented with the following modifications. This embodiment and the following modifications can be combined with each other to the extent that they do not contradict each other technically.

[0132] The terminal module 100 may have a temperature sensor that detects the temperature of the coil 93 by detecting the temperature of a busbar electrically connected to the coil 93. In this case, the placement of the temperature sensor can be appropriately selected according to the mounting requirements for the terminal module 100 on the stator 91. For example, the temperature sensor may be provided at the end of the terminal module 100 on one side Y1 in the second direction, or at the end of the other side Y2 in the second direction.

[0133] The shapes of each busbar 10, 20, 30, and 40 are not limited to those exemplified in this embodiment, and may be appropriately modified to suit the mounting requirements for the stator 91, within the scope of achieving the effects of this disclosure. For example, the second intermediate portion 42 of the fourth busbar 40 does not have to rise from the end of the first intermediate portion 41 on one side Y1 in the second direction, but may be a flat plate extending in both the second direction Y and the third direction Z.

[0134] The number of fourth busbars 40 is not limited to one, as illustrated in this embodiment, but may be two or more, for example. Furthermore, the fourth busbars 40 may be omitted. In this case, the fitting recesses 54A and 54B from the first retaining portion 51 can be omitted.

[0135] The first retaining portion 51 may have holes formed by, for example, a jig or positioning pin, in addition to the first holes 61a and 61b. Similarly, the second retaining portion 57 may have holes formed by, for example, a jig or positioning pin, in addition to the second hole 62.

[0136] The second retaining portion 57 is not limited to having a second hole 62 that communicates with the first holes 61a and 61b in the first direction X, as illustrated in this embodiment. In other words, the second hole 62 that communicates with the first holes 61a and 61b in the first direction X may be omitted from the second retaining portion 57.

[0137] The number and arrangement of the through holes 15, 25, 36, and 44 are not limited to those exemplified in this embodiment and may be appropriately changed to suit the shape of each bus bar 10, 20, 30, and 40. The communication hole 60 is not limited to having a second hole 62. That is, the second hole 62 may be omitted from the second holding portion 57. In this case, the through hole 36 can be omitted from the third busbar 30. Also, in this case, when forming the secondary mold body 102, the third busbar 30 may be held in place by a jig from both sides in the first direction X, for example.

[0138] The first holes 61a and 61b may be omitted. In this case, the through holes 15 and 25 from the first busbar 10 and the second busbar 20 can be omitted. Also in this case, when forming the primary mold body 101, for example, the first busbar 10 and the second busbar 20 can be sandwiched between jigs from both sides in the first direction X.

[0139] The first groove 55 may be omitted from the first retaining portion 51. The second groove 56 may be omitted from the first retaining portion 51. The bent portion 35 may be omitted from the third bus bar 30. Even in this case, the third bus bar 30 only needs to have an extended portion 33 that is located between the extended portion 13 of the first bus bar 10 and the extended portion 23 of the second bus bar 20 in the third direction Z.

[0140] The retaining member 50 is not limited to having a first retaining portion 51 and a second retaining portion 57. That is, the terminal module 100 may be such that each busbar is held collectively by the retaining member 50.

[0141] The legs 14b, 24b, and 34b of the intermediate sections 14, 24, and 34 of the busbars 10, 20, and 30 do not necessarily have to bend from the intermediate section bodies 14a, 24a, and 34a and extend in the first direction X away from the extended sections 13, 23, and 33. For example, the legs 14b, 24b, and 34b may bend from the intermediate section bodies 14a, 24a, and 34a and extend in the third direction inward Z1.

[0142] The protrusions 13a, 23a, and 33a are not limited to those located closer to the first end portions 11, 21, and 31 than to the central portion in the first direction X among the extended portions 13, 23, and 33. For example, the protrusions 13a, 23a, and 33a may be located in the central portion, or they may be located closer to the intermediate portions 14, 24, and 34 than to the central portion in the first direction X.

[0143] The number and arrangement of the protrusions 13a, 23a, and 33a may be changed as follows. For example, one of the protrusions 13a, 23a, and 33a may be omitted, or two of the protrusions 13a, 23a, and 33a may be omitted. In this embodiment, the example shows that the protrusions 13a, 23a, and 33a protrude from the end face Y1 on one side of the second direction of the extended portion 13, 23, and 33, but for example, they may be changed to protrude from the end face Y2 on the other side of the second direction, or one may protrude from each end face on both sides of the second direction Y.

[0144] The protrusions 13a, 23a, and 33a may be omitted. In this case, the recesses can be omitted from the holes 71a, 72a, and 73a of the connecting member 70. The connecting member 70 may be omitted.

[0145] The arrangement of the multiple busbars is not limited to that exemplified in this embodiment and can be appropriately changed to suit the mounting requirements for the stator 91. Even in this case, it is sufficient that the multiple busbars are arranged with spacing between them in the first direction X and side by side in the second direction Y.

[0146] The technical concept is described below. A terminal module for a rotating electric machine that electrically connects a stator constituting a rotating electric machine to a terminal block, comprising: a plurality of busbars integrally formed from a metal plate material; and a holding member formed from an electrically insulating resin that covers the plurality of busbars and is interposed between the plurality of busbars, wherein when the axial direction and circumferential direction of the rotating electric machine are defined as a first direction and a second direction, respectively, the plurality of busbars have a first end electrically connected to the terminal block, a second end electrically connected to the coil of the stator, an elongated extension portion located between the first end and the second end and extending in the first direction, and an intermediate portion located between the extension portion and the second end and covered by the holding member, and includes a first busbar, a second busbar, and a third busbar arranged side by side in the second direction, wherein the extension portion is configured to reduce vibrations transmitted from the stator toward the terminal block. [Explanation of Symbols]

[0147] C1 1st contact surface C2 Second contact surface C3 3rd 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 11 First end 11a Fastening hole 11b Nut 12 Second end 12a Flat plate part 12b Protrusion 13 Extension 13a Convex part 14. Middle section 14a Intermediate section body 14b Legs 15 Through holes 20 Second bus 21 First end 21a Fastening hole 21b Nut 22 Second end 22a Flat plate part 22b Protrusion 23 Extension 23a Convex part 24 Middle section 24a Intermediate section body 24b Legs 25 Through holes 30 Third Bus Bar 31 First end 31a Fastening hole 31b Nut 32 Second end 32a Flat plate part 32b Protrusion 33 Extension part 33a Convex part 34. Middle section 34a Intermediate section body 34b Legs 35. Bending section 35a Part 1 35b Part 2 36 Through holes 40 4th Bus 40A intermediate section 41. First Intermediate Section 42. Second Intermediate Section 43A, 43B, 43C 3rd end 43a Flat plate part 43b Protrusion 43c Slope 43d protrusion 44 Through holes 50 Retaining member 51 1st holding part 51A Base section 51a End face 51b End face 52. First Enclosure Section 53 Second Enclosure Section 53b End face 54A, 54B Mating recess 55 First groove 55a Bottom 55b side 56 Second groove 56a Bottom 56b Side 57 Second holding part 58 Base section 59 Third Enclosure Section 60 Communication hole 61a,61b 1st hole 62 2nd hole 70 Connecting member 71 Part 1 71a hole 71b Inner surface 71c recess 72 Part 2 72a hole 73 Part 3 73a hole 80 terminal block 81 1st terminal 81a one end 82 2nd terminal 82a one end 83 3rd terminal 83a one end 84 Housing 90 Rotating Electric Machine 91 stata 92 Stator Core 93 coils 100 terminal modules 101 Primary mold 102 Secondary mold 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 terminal module for a rotating electric machine that electrically connects the stator, which constitutes the rotating electric machine, to a terminal block, Multiple busbars integrally formed from metal sheet material, It comprises a retaining member formed of an electrically insulating resin that covers the plurality of busbars and is interposed between the plurality of busbars, When the axial direction and circumferential direction of the aforementioned rotating electric machine are defined as the first direction and the second direction, The aforementioned multiple busbars are The first end, which is electrically connected to the terminal block, The second end is electrically connected to the coil of the stator, A long, extended portion located between the first end and the second end and extending in the first direction, It includes a first busbar, a second busbar, and a third busbar, which are arranged side by side in the second direction, and have an intermediate portion located between the extended portion and the second end portion and covered by the retaining member, The first end and the extended portion are continuous and flat in shape, extending in the first direction. The extended portion is configured to reduce vibrations transmitted from the stator toward the terminal block. Terminal module for rotating electric machinery.

2. It includes a connecting member formed of an electrically insulating resin that integrally covers the extended portions of each of the first busbar, the second busbar, and the third busbar. A terminal module for a rotating electric machine as described in claim 1.

3. The connecting member has a plurality of holes through which each of the extended portions penetrates in the first direction. The extending portion of at least one of the first busbar, the second busbar, and the third busbar, and the connecting member, each have a restricting portion that restricts the relative movement of the connecting member with respect to the extending portion in the first direction by an arrangement of concave and concave parts. A terminal module for a rotating electric machine according to claim 2.

4. The restricting portion includes a protrusion projecting toward the inner circumferential surface of the hole from at least one of the extending portions of the first busbar, the second busbar, and the third busbar, and a recess formed on the inner circumferential surface. A terminal module for a rotating electric machine according to claim 3.

5. The aforementioned protrusion is provided in the extended portion at a position closer to the first end than to the central portion in the first direction. A terminal module for a rotating electric machine according to claim 4.

6. Each of the first busbar, the second busbar, and the third busbar has an elongated main body portion extending in the second direction, and a leg portion that bends from the main body portion and extends in the first direction opposite to the extended portion and is connected to the second end. A terminal module for a rotating electric machine as described in claim 1.

7. The retaining member has a first retaining portion that covers the first busbar and the second busbar and is interposed between the first busbar and the second busbar, and a second retaining portion that covers the first retaining portion and the third busbar. A terminal module for a rotating electric machine according to claim 6.

8. When the radial direction of the aforementioned rotating electric machine is defined as the third direction, The third busbar has a bent portion between the extended portion and the intermediate portion of the third busbar, The bent portion has a portion that bends from the extended portion and extends inward in the third direction. A terminal module for a rotating electric machine according to claim 7.

9. The first retaining portion has a groove into which a portion of the third busbar fits, The groove comprises a bottom surface against which the portion abuts, and a pair of side surfaces rising from both sides of the bottom surface in the second direction. The pair of sides sandwich the portion in the second direction. A terminal module for a rotating electric machine according to claim 7 or claim 8.

10. The plurality of busbars include a fourth busbar that is electrically connected to the neutral wire of the coil. The first holding portion includes a base portion having a first contact surface against which one end surface of the third busbar in the first direction abuts, and a second contact surface located on the opposite side of the first contact surface in the first direction, and against which the fourth busbar abuts. The second retaining part covers the fourth busbar. A terminal module for a rotating electric machine according to claim 7.

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