JP3359405B2 - Connector integrated stator for electromagnetic clutch - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a stator integrated with a connector of an electromagnetic clutch.

[0002]

2. Description of the Related Art As shown in FIG. 16, a connector-integrated stator of an electromagnetic clutch is provided in a housing portion of a stator housing 103 in a state in which a terminal 102a of a connector 102 is coupled to a spool 101 around which an exciting coil 100 is wound. When the mold resin 104 is injected into the housing portion after that, the connector 10 is
The second coupler 102b is also formed at the same time. The injection port (not shown) of the mold resin 104 injected into the housing is set at four equal intervals (90 degrees) in the circumferential direction of the housing, and the mold filled in the housing is filled. As shown in FIG. 17, four injection port traces 105 corresponding to the injection port are formed on the surface of the resin 104.

[0003]

However, in the above-described connector-integrated stator, the terminal 102a coupled to the spool 101 receives the pressure of the injected molding resin 104, so that if the rigidity of the terminal 102a is low, As shown in FIG. 16, the terminal 102a is not deformed and a predetermined size cannot be obtained.
Inconveniences such as exposure to the outside of 2b occur. This is １ ／ of the distance between the injection port traces 105 in the circumferential direction of the storage unit.
This is because the distance from the injection port trace 105 set near the connector 102 to the coupler 102b is larger. That is, the mold resin 104 injected from each injection port mark 105 is filled in the entire accommodating portion earlier than the coupler 102b, and the coupler 102b becomes a final filling portion. Accordingly, in the coupler 102b, a holding pressure (secondary molding pressure) is applied while the mold resin 104 is not yet solidified, and the holding pressure is applied to the terminal 102a, thereby deforming the terminal 102a as described above. Is generated. The present invention has been made based on the above circumstances,
It is an object of the present invention to provide a connector-integrated stator for an electromagnetic clutch that can prevent deformation of terminals due to injection of mold resin.

[0004]

In order to achieve the above object, the present invention comprises a stator housing having an annular accommodation portion having one end opened, and a coil wire wound around a spool. An injection coil housed in the housing, a terminal coupled to the spool and electrically connected to an end of the coil wire, and a connector comprising a holding unit for holding the terminal; In a connector-integrated stator of an electromagnetic clutch, wherein the holding portion is integrally formed on the other end side of the stator housing by a mold resin injected into the housing portion from a resin injection port of the means, the holding portion corresponds to the resin injection port. The distance at which the mold resin flows from the resin injection port to the holding section in the resin injection port of the storage section is equal to the distance of the resin injection port in the circumferential direction of the storage section. The longest distance between fat inlet 1/2
The means set at the following positions are technical means.

[0005]

According to the present invention having the above-described structure, the holding portion of the connector is integrally formed at the other end of the stator housing by the mold resin injected into the housing portion of the stator housing from the resin injection port of the resin injection means. Here, the resin injection port of the housing portion corresponding to the resin injection port of the resin injection means is
The distance at which the mold resin flows from the resin injection port to the holding portion of the connector is set to a position that is モ ー ル ド or less of the longest distance between the resin injection ports in the circumferential direction of the housing section. Therefore, when the mold resin is filled at a position farthest from the resin injection port in the circumferential direction of the housing portion, the holding portion is already filled with the mold resin.
That is, the holding portion does not become the final filling portion, and the position farthest from the resin injection port in the housing portion becomes the final filling portion.

[0006]

Next, an embodiment of an electromagnetic clutch having a connector-integrated stator according to the present invention will be described with reference to the drawings.
FIG. 1 is a sectional view of the electromagnetic clutch. The electromagnetic clutch 1 according to the present embodiment is mounted on a refrigerant compressor (not shown) of a refrigeration cycle for a vehicle, and transmits a rotating power of a stator 3 integrally formed with a connector 2 and an engine (not shown). The rotor 4 includes an armature 5 that faces the rotor 4 in the axial direction, an inner hub 7 that supports the armature 5 via a leaf spring 6, and the like.

The stator 3 includes an exciting coil 8 that generates a magnetic force when energized, and a stator housing 9 that supports the exciting coil 8. The excitation coil 8 is formed by winding a coil wire 11 (see FIGS. 5 and 6) provided with an insulating coating on a spool 10 formed of a thermoplastic resin (for example, nylon). ,
It is fixed by the mold resin 12. The method for manufacturing the stator 3 will be described in detail below.

The stator housing 9 is made of a magnetic material such as iron, and forms a magnetic path of the exciting coil 8 together with the rotor 4 and the armature 5 also made of a magnetic material. The stator housing 9 has an annular accommodating portion 9a (see FIGS. 7 and 8) having an open end (the left end in FIG. 1), and the exciting coil 8 is accommodated in the accommodating portion 9a. The stator housing 9 is fixed to the other end surface (the right end surface in FIG. 1) by welding to an annular arm support 13, and the arm support 13 is fixed to the housing 15 of the refrigerant compressor by the circlip 14, Axial positioning is performed.

The rotor 4 has a U-shaped cross section (an inverted U-shaped cross section in FIG. 1) for accommodating the stator 3, and has a housing 16 for the refrigerant compressor via a bearing 16 disposed on the inner periphery thereof. 15 rotatably supported. This rotor 4
The pulley 17 is fixed to the outer peripheral portion thereof by welding or the like, and is rotated by the rotational power of the engine transmitted via a multi-stage V-belt (not shown) stretched over the pulley 17. In addition, the rotor 4 has an armature 5
The one end surface in the axial direction opposite to the above is a friction surface.

The armature 5 comprises an annular inner ring 5a and an annular outer ring 5b which is arranged at a constant gap around the inner ring 5a. Each ring 5a, 5b is made of a non-magnetic material. Rivets 18 on the leaf springs 6
Has been fixed by. The armature 5 is arranged in the axial direction so as to face the friction surface of the rotor 4, and the other end surface of each of the rings 5a and 5b (the surface facing the friction surface of the rotor 4).
Are friction surfaces.

The inner hub 7 has a plate portion 7a having a substantially triangular planar shape and a cylindrical portion 7b provided at the center of the plate portion 7a. The cylindrical portion 7b is connected to a rotating shaft of the refrigerant compressor. 19 is fitted to the end of
It is fixed by. The above-mentioned leaf spring 6 is used for the rivet 2.
1 is fixed to the plate portion 7a of the inner hub 7. Therefore, the armature 5, the leaf spring 6, and the inner hub 7 rotate integrally with the rotating shaft 19 of the refrigerant compressor.

The leaf spring 6 urges the armature 5 in the direction away from the rotor 4 (to the left in FIG. 1) so as to cancel the frictional engagement between the armature 5 and the rotor 4 when the excitation coil 8 stops energizing. . A rubber stopper 22 for positioning the armature 5 urged by the leaf spring 6 when the excitation coil 8 is turned off is attached to the plate portion 7 a of the inner hub 7.

On the inner circumference of the armature 5 (the inner circumference of the inner ring 5a), a rubber suction noise reducing member 23 is disposed to reduce the suction noise generated when the armature 5 is sucked by the rotor 4. ing. This suction noise reducing member 23
Is supported by a metal support member 24, and one end face side is pressed by the leaf spring 6. The support member 24 is fixed to the plate portion 7a of the inner hub 7 by rivets 21 together with the leaf spring 6.

Here, a method of manufacturing the stator 3 will be described with reference to FIG.
This will be described with reference to FIG. First, a metal (for example, copper alloy) terminal 25 is pressed into a terminal insertion hole (not shown) formed in the spool 10 (see FIG. 2). In addition, the terminal insertion hole has a rectangular cross section,
Are provided at two predetermined positions in the circumferential direction.

As shown in FIGS. 3 and 4, the terminal 25 has a claw 25a for caulking and fixing the ends 11a and 11b (see FIG. 6) of the coil wire 11, and is inserted into the terminal insertion hole. On both sides of the rear end portion 25b (the left end portion in FIGS. 3 and 4), serrated protrusions 25c are provided to prevent the rear end portion 25b from coming out of the terminal insertion hole. In addition, the claw 2
Two constricted portions 25d for bending the terminal 25 into a predetermined shape are provided on the distal end side from 5a.

After inserting the terminal 25 into the terminal insertion hole, the coil wire 11 is wound around the spool 10 and the coil wire 11
After caulking and fixing both ends 11a and 11b of the winding start and end of the terminal 25 with the claw portion 25a of the terminal 25, as shown in FIG. As a result, the insulating coating of the coil wire 11 is broken by the heat generated during the energization, and the electrical connection between the coil wire 11 and the terminal 25 is made (see FIG. 6).

After the electrical connection between the coil wire 11 and the terminal 25 is made, the exciting coil 8 is housed in the housing 9a of the stator housing 9 together with the spool 10 (see FIG. 7). It is bent into a predetermined shape at 25d (see FIG. 8). Finally, a molding resin 12 is injected into the housing portion 9a of the stator housing 9 by an injection molding machine (not shown) (resin injection means of the present invention) to fix the exciting coil 8 and protect the terminal 25 by the molding resin 12. The connector 2 is integrally molded by simultaneously molding the cylindrical coupler 27 to be formed (see FIGS. 9 and 10).

Here, the molding resin 1 by the injection molding machine is used.
The injection of 2 is performed in two positions: a position closest to the connector 2 and a position farthest from the connector 2 in the circumferential direction of the housing portion 9a.
This is performed from a resin injection port (not shown) set at a certain location. Therefore, the mold resin 1 filled in the housing portion 9a
As shown in FIG. 11, two injection port traces 28 (the resin injection port of the present invention) corresponding to the resin injection port of the injection molding machine are formed on the surface of No. 2. This injection mark 28
Is shown in FIG.

As described above, by setting the resin injection port of the injection molding machine at two positions, that is, the position closest to the connector 2 and the position farthest from the connector 2, the tip of the coupler 27 from the resin injection port close to the connector 2 is set. The distance between the resin injection ports in the circumferential direction of the housing 9a is 1 /
The distance of 2 is larger. Therefore, the mold resin 12
Is assumed to be constant, the mold resin 12 is filled up to the tip of the coupler 27 earlier than the mold resin 12 is filled in the housing portion 9a farthest from each resin inlet. In other words, since the coupler 27 does not become the final filling portion of the mold resin 12, when the injection process shifts to the pressure holding process, the mold resin 12 filled in the coupler 27 has already started to solidify. The terminal 25 is not deformed due to the above.

Next, a second embodiment of the present invention will be described. FIG. 13 is a front view of the stator 3 as viewed from the opening side of the housing 9a. In this embodiment, the resin injection port of the injection molding machine is
Only one position is set at the position closest to the connector 2. As a result, only one injection port mark 28 is formed on the surface of the mold resin 12 of the housing portion 9a at a position closest to the connector 2 as shown in FIG. In the case of the present embodiment, the distance from the resin injection port to the furthest storage portion 9a is further longer than in the case of the first embodiment. Therefore, similarly to the first embodiment, the deformation of the terminal 25 can be prevented. In this case, in order to prevent the spool 10 from being exposed on the surface due to the resin pressure, it is necessary to increase the number of spool pressers (not shown). For the spool press, a projection may be provided on the mold of the injection molding machine, or a projection may be provided on the spool 10.

Next, a third embodiment of the present invention will be described. FIG. 14 is a front view of the stator 3 as viewed from the opening side of the housing 9a. In this embodiment, the resin injection port of the injection molding machine is
Two locations are set near the connector 2 and one location is set farthest from the connector 2, for a total of three locations. As a result, the surface of the molding resin 12 of the housing portion 9a is
As shown in (3), three injection port traces 28 are formed at positions corresponding to the resin injection ports. Also in the case of the present embodiment, the coupler 27
The portion does not become the final filling portion of the mold resin 12, so that the deformation of the terminal 25 in the pressure holding step can be prevented.

Next, a fourth embodiment of the present invention will be described. FIG. 15 is a front view of the stator 3 as viewed from the opening side of the housing portion 9a. In this embodiment, the resin injection port of the injection molding machine is
Three locations are set at equal intervals in the circumferential direction of the housing portion 9a, and one of the resin injection ports is set at a position closest to the connector 2. As a result, three injection port traces 28 are formed on the surface of the mold resin 12 of the housing 9a as shown in FIG. In the case of the present embodiment, the distance between the resin inlets is shorter than that of the first to third embodiments, but the distance between the resin inlets is still half that of the connector 2.
From the resin inlet set at the position closest to
Since the distance through which the mold resin 12 flows is larger than that, the portion of the coupler 27 does not become the final filling portion of the mold resin 12, and therefore, the deformation of the terminal 25 in the pressure holding step can be prevented.

[0023]

According to the present invention, the distance that the mold resin flows from the resin injection port of the housing section to the holding section of the connector is one of the longest distances between the resin injection ports in the circumferential direction of the housing section.
Since the resin injection port is set at a position of / 2 or less, the holding portion does not become the final filling portion. For this reason, in the pressure holding step, since the molding resin already filled in the holding portion has been solidified, the deformation of the terminal due to the resin pressure can be prevented. As a result, a predetermined terminal size can be secured without a part of the terminal being exposed to the outside of the holding portion.

[Brief description of the drawings]

FIG. 1 is a sectional view of an electromagnetic clutch.

FIG. 2 is a cross-sectional view showing a state where terminals are assembled to a stator housing.

FIG. 3 is a plan view of a terminal.

FIG. 4 is a side view of a terminal.

FIG. 5 is an explanatory diagram showing a process of electrical connection between a coil wire and a terminal.

FIG. 6 is a plan view showing an electrical connection state between a coil wire and a terminal.

FIG. 7 is a diagram showing a state in which an exciting coil is housed in a stator housing.

FIG. 8 is a diagram showing a state in which the terminal is bent into a predetermined shape.

FIG. 9 is a cross-sectional view of the stator in a state where the mold resin is filled.

FIG. 10 is a plan view of the stator viewed from the connector side.

FIG. 11 is a plan view of the stator as viewed from the opening side of the housing.

FIG. 12 is a cross-sectional view of an injection port trace of a mold resin.

FIG. 13 is a plan view of the stator seen from the opening side of the housing (second embodiment).

FIG. 14 is a plan view of the stator viewed from the opening side of the housing (third embodiment).

FIG. 15 is a plan view of a stator viewed from an opening side of a housing (fourth embodiment).

FIG. 16 is a cross-sectional view of a connector portion of a connector-integrated stator according to the related art.

FIG. 17 is a plan view of a stator according to the related art.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 Electromagnetic clutch 2 Connector 3 Connector integrated stator 8 Excitation coil 9 Stator housing 9a Housing part 10 Spool 11 Coil wire 11a End part 11b End part 12 Mold resin 25 Terminal 27 Coupler (holding part) 28 Injection mark (resin injection port)

Continuing on the front page (72) Inventor Toshimi Takeda 1-6-1-1, Shimomeguro, Meguro-ku, Tokyo Inside Dupont Corporation (72) Inventor Takashi Akagi 1-6-1-8-1, Shimomeguro, Meguro-ku, Tokyo (56) References JP-A-55-160958 (JP, A) JP-A-59-6672 (JP, A) JP-A-5-207711 (JP, A) JP-A-62-196053 (JP) JP-A-4-295258 (JP, A) JP-A-60-56830 (JP, U) (58) Fields investigated (Int. Cl. ⁷ , DB name) F16D 27/10 H02K 15/12

Claims (1)

(57) [Claims] A stator housing having an annular accommodation portion having an open end, a coil wire wound around a spool, an exciting coil accommodated in the accommodation portion together with the spool, and coupled to the spool. A terminal electrically connected to the end of the coil wire, and a connector comprising a holding portion for holding the terminal, wherein a molding resin injected into the housing portion from a resin injection port of a resin injection means. In the connector-integrated stator for an electromagnetic clutch, wherein the holding portion is integrally formed on the other end side of the stator housing, the resin injection port of the housing portion corresponding to the resin injection port is formed from the resin injection port. The position where the distance that the mold resin flows to the holding portion is 以下 or less of the longest distance between the resin injection ports in the circumferential direction of the housing portion. A connector integrated type stator for an electromagnetic clutch, wherein the stator is set.