Centralized power distribution unit for a vehicular thin brushless motor

• US 20030090166A1
• Filed: 10/28/2002
• Published: 05/15/2003
• Est. Priority Date: 10/26/2001
• Status: Active Grant

• Current Assignee: Honda Giken Kogyo Kabushiki Kaisha (Honda Motor Company), Sumitomo Wiring Systems Limited (Sumitomo Corporation)
• Original Assignee: Honda Giken Kogyo Kabushiki Kaisha (Honda Motor Company), Sumitomo Wiring Systems Limited (Sumitomo Corporation)
• Inventors: Kobayashi, Makoto, Fukuda, Kenji, Suzuki, Izumi, Horie, Tatsuro
• Granted Patent: US 6,930,418 B2
• Time in Patent Office: Days
• US Class Current: 310/144
• CPC Class Codes: H02K 2203/09 Machines characterised by wiring elements other than wires, e.g. bus rings, for connecting the winding terminations
• CPC Class Codes: H02K 3/522 for generally annular cores with salient poles
• CPC Class Codes: H02K 7/108 with friction clutches
• CPC Class Codes: H02K 7/1815 structurally associated with reciprocating piston engines general aspects of generating sets, e.g. housing, F02B63/04

Abstract

A centralized power distribution unit for a vehicular thin brushless motor includes a plurality of bus bars, an insulating holder that holds the bus bars to form a predetermined gap between the bus bars, and a resin insulating layer that covers the bus bars. Each of the bus bars has a terminal portion to be connected to a power source, such as a battery, and a tab to be connected to a winding of a stator. The bus bars are disposed correspondingly with phases of the motor. A plurality of holding grooves are formed in the insulating holder. The bus bars, which are pre-bent in a thickness direction to be shaped into a substantially annular shape, are respectively accommodated in the holding grooves. The pre-bending is preferably carried out by a bending machine.

Claims

1. A centralized power distribution unit for a vehicular thin brushless motor, wherein said centralized power distribution unit is formed into a ring configuration and can concentratedly distribute current to stator windings of the motor, the centralized power distribution unit comprising:

a plurality of bus bars, each having a terminal portion to be connected to a power source and one or more tabs to be respectively connected to one or more of the stator windings, the bus bars provided correspondingly with phases of the motor;

an insulating holder that holds the bus bars and maintains a predetermined gap between the bus bars; and

a resin insulating layer that covers the bus bars;

wherein

a plurality of holding grooves are provided in the insulating holder; and

the bus bars, which are pre-bent in a thickness direction to be shaped into a substantially annular shape, are respectively accommodated in the holding grooves.

2. The centralized power distribution unit according to claim 1, wherein each of the bus bars has an incomplete annular shape in which an arcuate portion is lacking.

3. The centralized power distribution unit according to claim 1, wherein

the bus bar has a main body;

the terminal portion protrudes from the main body;

the one or more tabs comprises a plurality of the tabs; and

an equal number of the tabs protrude from the main body on each side of the terminal portion.

4. The centralized power distribution unit according to claim 1, wherein at least one of the terminal portions includes a first section extending in a first direction that is a substantially radial direction of the centralized power distribution unit, a second section extending in a second direction substantially perpendicular to the first direction, and a ramp section connecting the first and second sections and extending in a third direction that is different from the first and second directions.

5. The centralized power distribution unit according to claim 1, wherein at least one slit is provided in at least one of the terminal portions.

6. The centralized power distribution unit according to claim 5, wherein a section of the at least one of the terminal portions is covered by a sealing material, and the at least one slit is provided in the section covered by the sealing material.

7. The centralized power distribution unit according to claim 5, wherein the at least one slit extends in a longitudinal direction of the terminal portion.

8. The centralized power distribution unit according to claim 1, wherein the bus bars are pre-bent by a bending machine and thereby are bent uniformly and are substantially free of localized bending stresses.

9. The centralized power distribution unit according to claim 1, wherein each of the bus bars includes n of the tabs, and a distance between adjacent ones of the tabs is substantially 1/n of the circumferential length of the centralized power distribution unit.

10. The centralized power distribution unit according to claim 1, wherein a distal end of each of the one or more tabs projects inwardly in a generally radial direction from an inner periphery of the centralized power distribution unit.

11. The centralized power distribution unit according to claim 1, wherein distal ends of the respective tabs are substantially equidistant from a center of the centralized power distribution unit.

12. The centralized power distribution unit according to claim 1, wherein the tabs of the respective bus bars are successively longer in length in a radial direction of the centralized power distribution unit, in order from an inside one of the bus bars to an outside one of the bus bars.

13. The centralized power distribution unit according to claim 1, wherein the tabs of at least one of the bus bars are each provided with a curved portion that goes around a top side of an adjacent one or more of the bus bars.

14. A method of producing a centralized power distribution unit for a vehicular thin brushless motor, wherein said centralized power distribution unit is formed into a ring configuration and can concentratedly distribute current to stator windings of the motor, the centralized power distribution unit comprising:

a plurality of bus bars, each having a terminal portion to be connected to a power source and one or more tabs to be respectively connected to one or more of the stator windings, the bus bars provided correspondingly with phases of the motor;

an insulating holder that holds the bus bars and maintains a predetermined gap between the bus bars; and

a resin insulating layer that covers the bus bars;

wherein a plurality of holding grooves are provided in the insulating holder; and

the bus bars, which are pre-bent in a thickness direction to be shaped into a substantially annular shape, are respectively accommodated in the holding grooves, the method comprising;

bending the bus bars into the substantially annular shape using a bending machine.