Mold module utilized as power unit of electric power steering apparatus and electric power steering apparatus
First Claim
1. A mold module utilized as a power unit of an electric power steering apparatus, formed by molding with a molding resin a plurality of lead frames for forming wiring leads and a plurality of electronic components mounted on the respective lead frames, wherein at least part of the plurality of lead frames are exposed at the rear side of the molding resin, andwherein the respective thicknesses of the plurality of lead frames are set in accordance with the thermal loss in the electronic component mounted on the lead frame such that the thickness of one lead frame of the plurality of lead frames is different than the thickness of at least one other lead frame of the plurality of lead frames.
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Accused Products
Abstract
There is provided a mold module and an electric power steering apparatus in which the temperature distribution in electronic components such as semiconductor chips utilized in an electronic relay and an inverter circuit unit is equalized and hence the heat radiation performance can be improved. In a mold module according to the present invention, a plurality of terminals for forming wiring leads and a plurality of electronic components mounted on the respective terminals are molded with a molding resin; at least part of the plurality of terminals are exposed at the rear side of the molding resin; an electric power steering apparatus according to the present invention utilizes the mold module.
20 Citations
17 Claims
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1. A mold module utilized as a power unit of an electric power steering apparatus, formed by molding with a molding resin a plurality of lead frames for forming wiring leads and a plurality of electronic components mounted on the respective lead frames, wherein at least part of the plurality of lead frames are exposed at the rear side of the molding resin, and
wherein the respective thicknesses of the plurality of lead frames are set in accordance with the thermal loss in the electronic component mounted on the lead frame such that the thickness of one lead frame of the plurality of lead frames is different than the thickness of at least one other lead frame of the plurality of lead frames.
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4. An electric power steering apparatus comprising:
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a speed reducing mechanism coupled with a steering shaft of a vehicle, a motor whose rotor shaft is coupled with the speed reducing mechanism, and a motor controller that controls electric power supplied to an armature winding of the motor so as to make the motor produce predetermined torque, wherein the motor controller is provided with a mold module in which a plurality of lead frames for forming wiring leads and a plurality of electronic components mounted on the respective lead frames are molded with a molding resin and in which at least part of the plurality of lead frames are exposed at the rear side of the mold resin, and wherein the rear side of the mold module is adhered to the case of the motor through the intermediary of a heat transfer resin, and wherein the mold module is provided with a protrusion that protrudes from the rear side, and the heat transfer resin is filled into a gap formed by the protrusion between the motor case and the rear side of the mold module. - View Dependent Claims (5, 6, 13, 14, 15, 16)
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7. An electric power steering apparatus comprising:
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a speed reducing mechanism coupled with a steering shaft of a vehicle, a motor whose rotor shaft is coupled with the speed reducing mechanism, and a motor controller that controls electric power supplied to an armature winding of the motor so as to make the motor produce predetermined torque, wherein the motor controller is provided with a mold module in which a plurality of lead frames for forming wiring leads and a plurality of electronic components mounted on the respective lead frames are molded with a molding resin and in which at least part of the plurality of lead frames are exposed at the rear side of the mold resin, and the rear side of the mold module is adhered to the motor case through the intermediary of a heat transfer resin including a filler, and wherein the gap between the motor case and the rear side of the mold module is secured by the filler.
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8. An electric power steering apparatus comprising:
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a speed reducing mechanism coupled with a steering shaft of a vehicle, a motor whose rotor shaft is coupled with the speed reducing mechanism, and wherein the motor controller is provided with a mold module in which a plurality of lead frames for forming wiring leads and a plurality of electronic components mounted on the respective lead frames are molded with a molding resin and in which at least part of the plurality of lead frames are exposed at the rear side of the mold resin, a heat sink, and a controller case that incorporates the mold module and the heat sink, wherein the rear side of the mold module is adhered to the heat sink through the intermediary of a heat transfer resin, wherein the heat sink has a heat sink opening portion formed at a position corresponding to a speed-reducing-mechanism-side case opening portion formed in the speed-reducing-mechanism case, and wherein a bus bar connected with the armature winding of the motor extends from the inside of the speed-reducing-mechanism-side case of the motor to the inside of the controller case by way of the speed-reducing-mechanism-side case opening portion and the heat sink opening portion and then is connected with the mold module in the controller case. - View Dependent Claims (9, 10, 11)
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12. An electric power steering apparatus comprising:
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a speed reducing mechanism coupled with a steering shaft of a vehicle, a motor whose rotor shaft is coupled with the speed reducing mechanism, and wherein the motor controller is provided with a mold module in which a plurality of lead frames for forming wiring leads and a plurality of electronic components mounted on the respective lead frames are molded with a molding resin and in which at least part of the plurality of lead frames are exposed at the rear side of the mold resin, a heat sink, and a controller case that incorporates the mold module and the heat sink, wherein the rear side of the mold module is adhered to the heat sink through the intermediary of a ceramic insulation sheet, and wherein the controller case is fixed to the speed-reducing-mechanism-side case of the motor.
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17. A mold module utilized as a power unit of an electric power steering apparatus, formed by molding with a molding resin a plurality of lead frames for forming wiring leads and a plurality of electronic components mounted on the respective front sides of the lead frames,
wherein at least part of the rear side, of each of the plurality of lead frames, that corresponds to one of the plurality of mounted electronic components is exposed at the rear side of the molding resin and the peripheral portion of the exposed part of each of the plurality of lead frames is covered with the molding resin, wherein a power terminal unit electrically connects a first electronic component of the plurality of electronic components with a first lead frame of the plurality of lead frames, and wherein a lead frame power line lead extended from the first lead frame, at least part of the rear side of which is exposed, is bent towards the front side of the first lead frame.
Specification