Method for producing centralized distribution unit of thin brushless motor for vehicle
First Claim
1. A method for producing a centralized distribution unit of a thin brushless motor for a vehicle wherein said centralized distribution unit is formed into a ring configuration and can concentratedly distribute current to stator windings, and said centralized distribution unit comprises:
- a plurality of bus bars, each of which includes a terminal portion to be connected to a battery and tabs to be connected to said stator windings, and is provided in conjunction with a phase of said motor;
an insulating holder having holding grooves that hold said respective bus bars and maintain a spacing between the bus bars, bearing recesses being provided in a bottom surface of said insulating holder beforehand; and
a resin insulation layer formed by insert-molding that covers said bus bars and said insulating holder,said method comprising the steps of;
disposing said insulating holder and said bus bars in a molding cavity in an insert-molding mold;
engaging distal ends of holder supports that project from an inner wall of a first mold member of the insert-molding mold with said bearing recesses; and
supplying a resin that forms said resin insulation layer into said molding cavity.
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Accused Products
Abstract
In a method of producing a centralized distribution unit of a thin brushless motor for a vehicle having superior waterproof-ness and airtight-ness functions, and high dielectric strength, an insulating holder is provided with bearing recesses. Bus bars are bent from a substantially linear shape into a substantially annular shape, and inserted into holding grooves formed in the insulating holder. The insulating holder and bus bars are disposed in a molding cavity, and distal ends of holder supports that project from an inner wall of the molding cavity are engaged with the bearing recesses of the insulating holder. Resin is supplied into the molding cavity to form an insulation layer that covers the bus bars and an entire periphery of the insulating holder.
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Citations
8 Claims
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1. A method for producing a centralized distribution unit of a thin brushless motor for a vehicle wherein said centralized distribution unit is formed into a ring configuration and can concentratedly distribute current to stator windings, and said centralized distribution unit comprises:
- a plurality of bus bars, each of which includes a terminal portion to be connected to a battery and tabs to be connected to said stator windings, and is provided in conjunction with a phase of said motor;
an insulating holder having holding grooves that hold said respective bus bars and maintain a spacing between the bus bars, bearing recesses being provided in a bottom surface of said insulating holder beforehand; and
a resin insulation layer formed by insert-molding that covers said bus bars and said insulating holder,said method comprising the steps of; disposing said insulating holder and said bus bars in a molding cavity in an insert-molding mold; engaging distal ends of holder supports that project from an inner wall of a first mold member of the insert-molding mold with said bearing recesses; and supplying a resin that forms said resin insulation layer into said molding cavity. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8)
- a plurality of bus bars, each of which includes a terminal portion to be connected to a battery and tabs to be connected to said stator windings, and is provided in conjunction with a phase of said motor;
Specification