Manufacturing method of circle type terminal used in driving motor of hybrid vehicle

The present invention relates to a manufacturing method of circle type terminal for driving motor of hybrid vehicle, comprising: assembling a terminal assembly having a plurality of bus-rings; accommodating the terminal assembly into an insert jig; coupling the insert jig with an injection mold; and supplying insert resin into the insert jig through the injection mold to integrally form an insulator with the terminal assembly thus performing manufacturing a circle type terminal, thereby providing a simple process to manufacture the circle type terminal and a method of forming an insulating material that can lower a manufacturing cost.

TECHNICAL FIELD

The present invention relates to a manufacturing method of a circle type terminal, and more particularly, to a manufacturing method of a circle type terminal which is used in a driving motor of a hybrid vehicle.

BACKGROUND ART

A DC brushless motor used as a driving motor in a hybrid vehicle comprises a circle type terminal which has a plurality of copper-made conductors (hereinafter “bus-ring”).

The circle type terminal uses a three-phase current to supply to eighteen stator coils for driving a motor.

In this case, an insulating material is used for insulating between phases and also between the terminal and other outside parts.

Conventionally, a coating type insulating material was used for the bus-rings of the circle type terminal.

That is, to manufacture a conventional circle type terminal, a terminal assembly comprising a plurality of bus-rings is assembled, and then the coating type insulating material such as silicon is coated on top of the bus-rings for insulating between the bus-rings.

However, according to the conventional method where the silicon is applied to form the insulating material of the circle type terminal, a manufacturing cost rises due to a high price of the silicon and due to a generation of much loss during coating of the silicon.

Also, the insulating material formed by coating the silicon shows a low level of oil resistance and a low level of insulating resistance due to a generation of air bubbles, thus causing problems in securing credibility on operation.

DISCLOSURE

Technical Problem

The present invention is proposed to solve the above problems for a circle type terminal and it is an aspect of the present invention to provide a manufacturing method of the circle type terminal where only a simple process is used to manufacture the circle type terminal.

Also, it is another aspect of the present invention to provide a manufacturing method of the circle type terminal where a plastic injection resin is used to form an insulating material to lower a manufacturing cost compared to using silicon.

Also, it is another aspect of the present invention to provide a circle type terminal which secures a product credibility by being equipped with a sufficient oil resistance and heat resistance in a condition of driving a hybrid vehicle where it is adopted.

Technical Solution

The foregoing and/or other aspects of the present invention can be achieved by providing a manufacturing method of circle type terminal for driving motor of hybrid vehicle, comprising: assembling a terminal assembly having a plurality of bus-rings; accommodating the terminal assembly into an insert jig; coupling the insert jig with an injection mold; and supplying insert resin into the insert jig through the injection mold to integrally form an insulator with the terminal assembly thus performing manufacturing a circle type terminal.

According to an aspect of the present invention, the insert jig comprises an upper insert jig and a lower insert jig which are coupled together, the upper insert jig is formed with an injection resin flow groove to correspond to the insulator, the lower insert jig is formed with an accommodating groove to accommodate the terminal assembly.

According to an aspect of the present invention, the injection mold comprises an upper injection mold and lower injection mold which is covered by the upper injection mold, the lower injection mold has a jig accommodating depression in which the insert jig is accommodated.

According to an aspect of the present invention, the injection mold comprises an upper injection mold and a lower injection mold which are coupled together, the upper injection mold is formed with an upper insert jig accommodating depression in which the upper insert jig is accommodated, the lower injection mold is formed with a lower insert jig accommodating depression in which the lower insert jig is accommodated.

Advantageous Effects

According to the manufacturing method of the circle type terminal of the present invention described above, a plastic injection resin is supplied to form an insulating material of the circle type terminal, so that a manufacturing cost can be lowered and a manufacturing process can be simplified compared to a conventional method where a silicon is used.

Also, as an insert jig can be easily attached to and detached from an insert mold, various sizes and shapes of the circle type terminal can be manufactured by simply substituting the insert jigs which have different inside formations.

Also, though the silicon forming the conventional insulating material shows characteristics that it is considerably weakened in strength when a heat or gasoline is introduced, the plastic injection resin is resistant to the heat, gasoline and etc. to secure a credibility in a condition of driving a driving motor where the circle type terminal is used.

BEST MODE

Hereinafter, an exemplary embodiment of the present invention will be described by referring to the accompanying figures.

As shown inFIG. 1andFIG. 2, a circle type terminal manufacturing device10, which an exemplary embodiment of the present invention is applied to, comprises an insert jig200where a terminal assembly100is accommodated and an injection resin to be an insulator410(seeFIG. 6) is introduced thus forming a circle type terminal400(seeFIG. 6), and an injection mold300which receives and supports the insert jig200to be detachable.

As shown inFIG. 4, the terminal assembly100comprises a plurality of bus-rings120,130,140and150(seeFIG. 5) that are assembled to have a shape of a circle respectively to confirm with a driving motor.

As shown inFIG. 5, the terminal assembly100according to the exemplary embodiment of the present invention is provided to have four bus-rings120,130,140and150to be assembled with each other.

The bus-rings120,130,140and150are made of a copper alloy.

To assemble the terminal assembly100, as shown inFIG. 4, four bus-rings120,130,140and150(seeFIG. 5) are coupled to a terminal main body110and then a plurality of spacers160are inserted into the terminal main body110to be spaced with each other in a circular direction thus maintaining an insulation gap between the bus-rings120,130,140and150as shown inFIG. 5.

Each of the bus-rings120,130,140and150has a different diameter to be disposed concentrically.

The spacer160has its shape to be inserted between the bus-rings120,130,140and150and is disposed at a predetermined interval along the bus-rings120,130,140and150.

When the spacers160are inserted, a cover170is attached to a side of the terminal main body110as shown inFIG. 4thus completing assembling of the terminal assembly110.

Then, as shown inFIG. 2, the terminal assembly110is inserted into the insert jig200.

As shown inFIG. 2andFIG. 3, the insert jig200accommodates the terminal assembly100therein and then the injection resin is introduced to form the insulator410(seeFIG. 6) on top of the terminal assembly100.

The insert jig200has an injection resin flow hole211to correspond to a shape of the insulator410.

The insert jig200comprises an upper insert jig210and a lower insert jig220.

The lower insert jig220has an inner accommodating groove221to correspond to the shape of the terminal main body110(seeFIG. 4) of the terminal assembly100to accommodate the terminal assembly100.

In this case, the injection resin can not be introduced into the lower insert jig220as the terminal assembly100is tightly accommodated in the inner accommodating groove221(refer toFIG. 5).

As shown inFIG. 5, the upper insert jig210has an injection resin flow groove211to correspond to the shape of the insulator410of the circle type terminal400.

The injection resin which is introduced through the injection resin flow groove211is supplied evenly on top of the terminal assembly100to be the insulator410that is integrally formed with the terminal assembly100.

Therefore, the insulator410formed on top of the terminal assembly100performs insulating a plurality of the bus-rings120,130,140,150therebetween.

The injection resin flow groove211communicates with the injection resin supplying hole213.

The injection resin supplying hole213passes through the upper insert jig210to be supplied with the injection resin through the injection mold300(seeFIG. 1).

As shown inFIG. 2andFIG. 3, the insert jig200is made to order to form the insulator410that corresponds to the shape of the each terminal assembly100.

The insert jig200is provided to be attached to and detached from the injection mold300.

That is, when the insert jig200accommodates the terminal assembly100, it is coupled to the injection mold300to be supplied with the injection resin.

And when the injection molding is finished, the insert jig200is separated from the injection mold300thus enabling separation of the circle type terminal400which is made by integrally forming the terminal assembly100and the insulator410.

As shown inFIG. 1andFIG. 2, the injection mold300comprises an upper injection mold310and a lower injection mold320and accommodates the insert jig200therein.

The injection mold300supports the insert jig200so that the injection resin can be supplied into the insert jig200to form the terminal assembly100and the injection resin integrally.

The upper injection mold310covers and uncovers the lower injection mold320.

The lower injection mold320accommodates and supports the insert jig200.

The lower injection mold320has a jig accommodating depression321to accommodate the insert jig200.

The insert jig200is made of a material that is light and durable such as duralumin.

The insert jig200has a uniform shape outwardly, but may have various shapes inwardly according to various shapes of the terminal assembly100.

Therefore, with only one injection mold300, various insert jigs200having different inner shapes therebetween can be coupled for manufacturing various kinds of circle type terminals.

The insert jig200can be coupled to the injection mold300by means of bolts and nuts that are provided to the insert jig200, by insertion of ribs and holes, by interference fit between the insert jig200and the injection mold300or by any other way.

The injection mold300, unlike in this exemplary embodiment of the present invention, may have the upper injection mold310which accommodates the upper insert jig210and the lower injection mold320which accommodates the lower insert jig220.

Hereinafter, a manufacturing method of the circle type terminal400by using the circle type terminal manufacturing device10described above.

That is, as shown inFIG. 4, a plurality of the bus-rings120,130,140and150(seeFIG. 5) are assembled together into the terminal main body110.

Then, the spacers160are inserted to be interposed between a plurality of the bus-rings120,130,140and150.

In a state that the insulation gap is maintained between a plurality of the bus-rings120,130,140and150by the spacers160, the cover170is attached to the terminal main body110.

If the assembling of the terminal assembly100is finished by attachment of the cover170, the terminal assembly100is accommodated into the insert jig200(refer toFIG. 2).

That is, the terminal assembly100is accommodated in the inner accommodating groove221of the lower insert jig220and the upper insert jig210is coupled to the lower insert jig220as shown inFIG. 3.

Alternatively, according to another exemplary embodiment, the upper insert jig210may be accommodated into an accommodating depression (not shown) of the upper injection mold310and the lower insert jig220may be accommodated into an accommodating depression (refer to321) of the lower injection mold320.

As shown inFIG. 1, when fixing of the insert jig200and the injection mold300is finished, the injection resin is introduced.

The injection resin is introduced into the insert jig200through the injection mold300.

That is, as shown inFIG. 5, the injection resin that is supplied through the injection resin supplying hole213of the upper insert jig210is supplied to the upper surface of the terminal assembly100that is accommodated in the insert jig210and220.

Accordingly, the injection resin is integrally formed with the terminal assembly100to form the insulator410(seeFIG. 6).

When an insert injection molding is finished as described above, the insert jig200is separated from the injection mold300.

The upper insert jig210and the lower insert jig220are separated from each other to extract the circle type terminal400(seeFIG. 6) that is formed by integrally forming the terminal assembly100and the insulator410(refer toFIG. 2).

The circle type terminal400formed by performing the injection molding is manufactured in a condition that the injection resin is uniformly supplied over all of the upper surface of the terminal assembly100by injection pressure, so that a thickness of the insulator410can be maintained constant.

Although the exemplary embodiment of the present invention has been shown, it will be appreciated by those skilled in the art that changes may be made in the exemplary embodiment without departing from the principles and spirit of the invention, the scope of which is defined in the appended claims and their equivalents.