JP2008199740A - Fuel pump and manufacturing method thereof - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a fuel pump which can easily be manufactured and whose manufacture manhour can be reduced, and to provide a manufacturing method of the pump. <P>SOLUTION: One end 74a of a choke coil 70 is electrically connected to a power supply-side terminal 60, and the other end 74b of the choke coil 70 is electrically connected to a brush-side terminal 64. The brush-side terminal 64 is electrically connected to a brush 76 through a pigtail 78. The power supply-side terminal 60 and the brush-side terminal 64 are formed by cutting a coupling part 300 of a terminal base material 100. A cutting face 63 of the power supply-side terminal 60 after the coupling part 300 is cut and a cutting face 68 of the brush-side terminal 64 are confronted each other in a state where they are assembled to a holder. The coupling part 300 of the terminal base material 100 is cut in a state where a structure in which both ends of a coil main body 74 are electrically connected to choke coil connection parts 61 and 65 of the terminal base material 100 is assembled to the holder. <P>COPYRIGHT: (C)2008,JPO&INPIT

Description

  The present invention relates to a fuel pump that drives a pump unit by a rotational driving force of a motor unit and a method for manufacturing the fuel pump.

  2. Description of the Related Art Conventionally, a fuel pump that uses a brush motor as a motor unit that drives a pump unit that boosts fuel is known (see, for example, Patent Document 1). In the brush motor, a driving current is supplied from the power supply side terminal to the armature of the motor unit through the choke coil, the brush side terminal, the pigtail, the brush, and the commutator. The power supply side terminal is supplied with electric power from an external power supply cable or the like and is electrically connected to one end of the choke coil. The brush side terminal is electrically connected to the other end of the choke coil and the pigtail. The power supply side terminal and the brush side terminal are separate electrical terminals and are insulated. When the choke coil is not used, it is conceivable that the power supply side terminal and the brush side terminal are electrically connected by a lead wire or a connection terminal.

  However, the work of assembling the separate power supply side terminal and brush side terminal to the mounting member of the motor unit is complicated, and the number of manufacturing steps increases. In addition, when the power supply side terminal and the brush side terminal are electrically connected to the choke coil, lead wire, connection terminal or the like before being assembled to the motor unit, the power supply side terminal and the brush side terminal, which are separate members, are cured. Since it is necessary to perform the connection work while being fixed to a tool or the like, the connection work is complicated and the number of manufacturing steps increases.

JP-A-6-205568

  The present invention has been made to solve the above problems, and an object of the present invention is to provide a fuel pump that is easy to manufacture and reduces the number of manufacturing steps, and a manufacturing method thereof.

In the following description, the term “integral” refers to both one member or one structure formed by combining a plurality of members.
In the first aspect of the present invention, the power supply side terminal and the brush side terminal that are electrically connected to the choke coil at the choke coil connecting portion are formed by being cut from the integrally formed state. That is, the power supply side terminal, the brush side terminal, and the choke coil can be electrically connected in a state before cutting in which the power supply side terminal and the brush side terminal are integrally formed. This facilitates the electrical connection work between the power supply side terminal and the brush side terminal and the choke coil as compared with the case where the power supply side terminal and the brush side terminal and the choke coil are electrically connected as separate members. Is reduced.

  In invention of Claim 2, it cut | disconnects from the state formed integrally, a power supply side terminal and a brush side terminal are formed, and the cut surfaces of a power supply side terminal and a brush side terminal are installed facing each other. Yes. In other words, the power supply side terminal, the brush side terminal and the choke coil are electrically connected in a state of being integrally formed before cutting, and in this state, the power supply side terminal and the brush side terminal are assembled to the mounting member of the motor unit. Therefore, the power supply side terminal and the brush side terminal can be easily assembled to the mounting member as compared with the case where the power supply side terminal and the brush side terminal are separate members.

  In the third aspect of the invention, the electrical connection location between the choke coil and the power supply side terminal and the electrical connection location between the choke coil and the brush side terminal are covered with the mold resin. To prevent exposure. Thereby, corrosion of the electrical connection location of a power source side terminal, a brush side terminal, and a choke coil can be prevented.

  In the invention described in claim 3, the mold resin has a cut surface on the same plane following the cut surfaces of the power supply side terminal and the brush side terminal. That is, the power supply side terminal and the brush side terminal that are integrally formed are each electrically connected to the choke coil, and the electrical connection portion is covered with the mold resin and then cut including the mold resin. Therefore, the molding operation is easier than the case where the power supply side terminal and the brush side terminal, which are separate members, and the choke coil are electrically connected and then the respective electrical connection portions are covered with the molding resin.

  In the invention according to claim 4, since the mold resin couples the electrical connection portions of the power supply side terminal, the brush side terminal and the choke coil, whether or not the power supply side terminal and the brush side terminal are cut off. Regardless, the power supply side terminal, the brush side terminal, and the choke coil can be assembled to the mounting member of the motor unit as a structure coupled with the mold resin. Thereby, the assembly work is easy and the number of manufacturing steps is reduced.

  According to the fifth aspect of the present invention, in the electric terminal in which the power supply side terminal and the brush side terminal are integrally formed, the choke coil connection portion that is electrically connected to the choke coil when the choke coil is used is the power supply side. Terminals and brush-side terminals are provided respectively. According to the configuration of this electric terminal, when the choke coil is not used, the electric terminal in which the power supply side terminal and the brush side terminal are integrally formed may be assembled to the mounting member of the motor unit. In addition, the brush-side terminal can be assembled to the mounting member of the motor unit by one assembling operation. Thereby, the assembly work of the power supply side terminal and the brush side terminal is facilitated, and the number of manufacturing steps is reduced. On the other hand, when using the choke coil, the integrally formed electrical terminal can be cut into a power supply side terminal and a brush side terminal.

  In the invention according to claim 6, since the power supply side terminal and the brush side terminal of the terminal base material formed integrally and the choke coil are electrically connected, the power supply side terminal and the brush side terminal of the separate member and the choke are connected. Compared with the case where the coil is electrically connected, the electrical connection work between the power supply side terminal and the brush side terminal and the choke coil is facilitated, and the number of manufacturing steps is reduced.

In the invention according to claim 7, since the terminal base material and the choke coil are assembled to the mounting member of the motor portion in a state before the terminal base material and the choke coil are electrically connected, the power source side terminal and the brush side terminal And the choke coil can be easily assembled to the mounting member of the motor unit, and the number of manufacturing steps can be reduced.
In the invention according to claim 8, in the state of the terminal base material in which the power supply side terminal and the brush side terminal are integrally formed after the connection step and before the cutting step and the assembly step, Since the two electrical connection locations of the brush side terminal and the choke coil are covered with the mold resin, the power source side terminal and the brush side terminal of the separate member and the choke coil are electrically connected, and then each electrical connection Compared with the case where the portion is covered with the mold resin, the molding operation is easier.

  In the ninth aspect of the invention, in the molding step, the molding resin joins two electrical connection portions of the power supply side terminal, the brush side terminal, and the choke coil. Thus, regardless of whether the cutting process is before or after the assembling process, the power supply side terminal and the brush side terminal combined with the mold resin can be assembled as one structure to the mounting member of the motor unit. Thereby, the power supply side terminal, the brush side terminal, and the choke coil can be easily assembled to the mounting member of the motor unit, and the number of manufacturing steps can be reduced.

Hereinafter, embodiments of the present invention will be described with reference to the drawings.
(First embodiment)
FIG. 2 shows the configuration of the fuel pump according to the first embodiment. The fuel pump 10 is an in-tank type turbine pump accommodated in a fuel tank (not shown) mounted on, for example, a two-wheeled vehicle or a four-wheeled vehicle. The fuel pump 10 boosts the pressure of the fuel sucked from the fuel tank and supplies it to the engine side.

  The fuel pump 10 includes a pump unit 12 and a motor unit 13 that rotationally drives the pump unit 12. The housing 14 also serves as a housing for the pump unit 12 and the motor unit 13, and caulks the pump case 20 and the end cover 90 at both ends in the axial direction. As the housing 14 caulks the end cover 90, the holder 80 is sandwiched between the end cover 90 and the housing 14.

  The pump unit 12 includes pump cases 20 and 22 and an impeller 30. The pump unit 12 is installed on one side in the axial direction with respect to the armature 50, and the impeller 30 is assembled to the shaft 52 of the armature 50. When the impeller 30 as the rotating member rotates together with the armature 50, the fuel sucked from the inlet 200 is repeatedly flown out and inflow from the blade groove at the front in the rotation direction toward the blade groove at the rear in the rotation direction. The swirl flow is increased in pressure by the pump passage 202.

  The fuel pressurized in the pump passage 202 passes through the fuel passage 204 formed between the permanent magnet 40 and the armature 50 and the fuel passage 206 formed in the holder 80, and passes through the fuel discharge port 208 formed in the end cover 90 to the engine. Supplied to the side. A check valve 92 is accommodated in the fuel discharge port 208, and the check valve 92 prevents the backflow of fuel discharged from the fuel discharge port 208.

  The motor unit 13 is a so-called brush motor, and includes a permanent magnet 40, an armature 50, a commutator 54, a power supply side terminal 60, a brush side terminal 64, a choke coil 70, a brush 76, a pigtail 78, and the like shown in FIG. ing. The permanent magnets 40 are formed in an arc shape and are attached to the inner peripheral wall of the housing 14 in the circumferential direction. The permanent magnet 40 forms two magnetic poles having different poles in the circumferential direction. Between the two permanent magnets 40 installed in the circumferential direction, a leaf spring 42 and a support part 82 of the holder 80 extending from the commutator 54 side to the pump part 12 side are installed. The leaf spring 42 and the support portion 82 prevent the circumferential displacement of the permanent magnet 40.

The armature 50 is rotatably installed on the inner peripheral side of the permanent magnet 40. The end of the armature 50 on the side of the pump portion 12 in the axial direction of the shaft 52 is supported by the bearing 24. The bearing 24 is supported by the pump case 22. The other end portion of the shaft 52 in the axial direction is directly supported by the bearing portion 84 of the holder 80.
The commutator 54 is formed in a flat disk shape and has a plurality of segments installed in the rotation direction. A drive current is supplied from the power supply side terminal 60 to the coil of the armature 50 through the choke coil 70, the brush side terminal 64, the pigtail 78, the brush 76, and the commutator 54.

  As shown in FIG. 1, the choke coil 70 includes a choke core 72 and a coil body 74 wound around the choke core 72. The power supply side terminal 60 has a choke coil connection portion 61 that is electrically connected to one end 74 a of the coil body 74. Further, the brush side terminal 64 has a choke coil connection portion 65 that is electrically connected to the other end 74 b of the coil body 74, and an electrical connection portion 66 that is electrically connected to the pigtail 78. . The power supply side terminal 60 and the brush side terminal 64 have legs 62 and 67 supported by a holder 80 as an attachment member. The structures shown in FIG. 1 are installed on the + pole and the -pole, respectively.

The power supply side terminal 60 and the brush side terminal 64 are formed by cutting the connecting portion 300 of the terminal base material 100 shown in FIG. The cut surface 63 of the power supply side terminal 60 after cutting the coupling part 300 and the cut surface 68 of the brush side terminal 64 face each other in a state of being assembled to the holder 80.
The holder 80 and the end cover 90 shown in FIG. 2 are each integrally formed of an insulating resin. For example, the holder 80 is integrally formed of PPS (polyphenylene sulfide), and the end cover 90 is integrally formed of POM (polyacetal). The relief valve 94 opens when the discharge pressure of the fuel pump 10 exceeds a predetermined pressure, and sets the discharge pressure of the fuel pump 10 to a predetermined pressure or less.

Next, a manufacturing process of assembling the power supply side terminal 60, the brush side terminal 64, the choke coil 70, the brush 76, and the pigtail 78 to the holder 80 of the motor unit 13 will be described.
(1) Connection Step Both ends of the coil body 74 are electrically connected to the choke coil connection portions 61 and 65 of the terminal base material 100 shown in FIG. Connection points between the choke coil connecting portions 61 and 65 and the coil body 74 are fixed by caulking. Instead of caulking, the connection location between the choke coil connecting portions 61 and 65 and the coil body 74 may be fixed by solder.

(2) Assembly process A structure in which the choke coil 70 and the terminal base material 100 are electrically connected is assembled to the holder 80.
(3) Cutting process In a state in which the structure in which the choke coil 70 and the terminal base material 100 are electrically connected is assembled to the holder 80, the coupling portion 300 of the terminal base material 100 is cut.
In the manufacturing process, the brush 76 and the pigtail 78 may be electrically connected to the brush side terminal 64 in the connection process, or the structure is assembled to the holder 80 in the assembly process and then the brush side terminal 64 is electrically connected. May be connected.

  In contrast to the first embodiment, in the comparative example shown in FIG. 3, the choke coil 70 is electrically connected to the power supply side terminal 110 and the brush side terminal 112 which are separate members, and then assembled to the holder 80. In this case, since it is necessary to fix the power supply side terminal 110 and the brush side terminal 112 which are separate members to a jig etc. and to electrically connect with the choke coil 70, the electrical connection work is complicated and the number of manufacturing steps is reduced. Will increase. When the choke coil 70 is not used, the power supply side terminal 110 and the brush side terminal 112 are electrically connected by a lead wire or a connection terminal instead of the choke coil 70, so that the choke coil 70 is connected similarly. In addition, the electrical connection work is complicated and the number of manufacturing steps increases.

Further, since it is necessary to assemble the power supply side terminal 110 and the brush side terminal 112, which are separate members, to the holder 80, the assembly work is complicated and the number of manufacturing steps increases.
On the other hand, in the first embodiment, the power supply side terminal 60, the brush side terminal 64, and the choke coil 70 are electrically connected in the state of the terminal base material 100 in which the power supply side terminal 60 and the brush side terminal 64 are integrally formed. Since the connection is made, the electrical connection work between the power supply side terminal 60 and the brush side terminal 64 and the choke coil 70 is easy, and the number of manufacturing steps can be reduced. Further, since the structure in which the terminal base material 100 and the choke coil 70 are electrically connected is assembled to the holder 80, the power supply side terminal 60, the brush side terminal 64, and the choke coil 70 can be easily assembled to the holder 80. Can do.

In contrast to the first embodiment, in the case of a fuel pump that does not use the choke coil 70, the terminal base material 100 shown in FIG. 1B may be used as it is assembled to the holder 80 without being cut. Therefore, as compared with the configuration in which the power supply side terminal 110 and the brush side terminal 112 are assembled to the holder 80 even when the choke coil 70 is not used as in the comparative example of FIG. 80 can be easily assembled.
Thus, since the terminal base material 100 which is a common component can be used regardless of the presence or absence of the choke coil 70, the manufacturing cost of the fuel pump is reduced.

(Second Embodiment)
A second embodiment of the present invention is shown in FIG. In addition, the same code | symbol is attached | subjected to the substantially same component as 1st Embodiment.
The mold resin 120 includes two electrical connection points between the coil body 74, the power supply side terminal 60, and the brush side terminal 64 (not shown in FIG. 4), and the brush side terminal 64 and the pigtail. A total of three electrical connection locations of electrical connection locations with 78 are covered and the three electrical connection locations are coupled. The power supply side terminal 60 and the brush side terminal 64 are formed by cutting the connecting portion 302 of the terminal base material 100 shown in FIG. Since the cutting location of the terminal base material 100 is different from that of the first embodiment, the shapes of the power supply side terminal 60 and the brush side terminal 64 of the second embodiment are different from those in FIG.

Next, a manufacturing process for assembling the power supply side terminal 60, the brush side terminal 64, the choke coil 70, the brush 76, the pigtail 78 and the mold resin 120 to the holder 80 of the motor unit 13 will be described.
(1) Connection Step As shown in FIG. 1A, the choke coil 70 and the pigtail 78 are electrically connected to the terminal base material 100 shown in FIG. 1B, and the brush 76 and the pigtail 78 are connected. Connect electrically.
(2) Molding process After the connecting process, a total of 3 electrical connection locations of the coil body 74, the power supply side terminal 60 and the brush side terminal 64, and the electrical connection location of the brush side terminal 64 and the pigtail 78 The mold resin 120 is molded so as to cover the three electrical connection locations and to bond the three electrical connection locations.

(3) Assembly process The structure formed by molding the mold resin 120 in the molding process is a structure in which the cut portion 122 is filled in FIG. 4, and the structure is assembled to the holder 80. (4) Cutting Step The joint portion 302 of the terminal base material 100 shown in FIG. As a result, the cut surface of the power supply side terminal 60 and the cut surface 123 of the mold resin 120 formed by cutting the coupling portion 302 of the terminal base material 100, and the cut surface of the brush side terminal 64 and the cut surface 124 of the mold resin 120 are formed. Are continuously on the same plane. The cut surface of the power supply side terminal 60 and the cut surface of the brush side terminal 64 face each other.

  In the second embodiment, there are a total of three electrical connections including two electrical connection locations of the coil body 74, the power supply side terminal 60 and the brush side terminal 64, and the electrical connection location of the brush side terminal 64 and the pigtail 78. Since the molding resin 120 covers the connection portion, the electrical connection portion can be prevented from corroding in the fuel. In particular, when an alcohol that easily corrodes a metal is used as a fuel, it is desirable to cover an electrical connection portion with a mold resin 120.

In the second embodiment, similarly to the first embodiment, the choke coil 70 is electrically connected to the terminal base material 100 formed integrally before being cut into the power supply side terminal 60 and the brush side terminal 64. Therefore, the electrical connection work between the power supply side terminal 60 and the brush side terminal 64 and the choke coil 70 is easy, and the number of manufacturing steps can be reduced.
In addition, since the electrical connection portion is molded with the mold resin 120 in a state where the choke coil 70 is electrically connected to the terminal base material 100, the terminal base material 100 is cut into the power source side terminal 60 and the brush side terminal 64. Compared to the case of molding from the mold, the molding work is easy and the number of manufacturing steps is reduced.

Furthermore, since the structure in which the terminal base material 100 and the choke coil 70 are electrically connected is assembled to the holder 80 in a state where the mold resin 120 is coupled to the electrical connection portion, the power supply side terminal 60 and the brush side terminal 64 are assembled. And the choke coil 70 can be easily assembled to the holder 80.
Also in the second embodiment, since the power source side terminal 60 and the brush side terminal 64 are formed by cutting the same terminal base material 100 as in the first embodiment, the parts can be shared.

(Other embodiments)
In the first embodiment, the terminal base material 100 electrically connected to the choke coil 70 is assembled to the holder 80, and then the terminal base material 100 is cut into the power supply side terminal 60 and the brush side terminal 64. On the other hand, the terminal base material 100 electrically connected to the choke coil 70 may be cut into the power supply side terminal 60 and the brush side terminal 64 and then assembled to the holder 80.

  Further, in the second embodiment, the terminal base material 100 is cut into the power supply side terminal 60 and the brush side terminal 64 after assembling the structure whose electrical connection portions are covered with the mold resin 120 to the holder 80. On the other hand, before assembling the structure in which the electrical connection portions are covered with the mold resin 120 to the holder 80, the terminal base material 100 is connected to the power source side terminal while maintaining the state where the electrical connection locations are coupled with the mold resin 120. 60 and the brush-side terminal 64 may be cut.

  As described above, the present invention is not limited to the above-described embodiment, and can be applied to various embodiments without departing from the gist thereof. For example, the characteristic structures of the above-described embodiments are arbitrarily combined. It may be.

(A) is a perspective view which shows the electrical pathway from the power supply side terminal of 1st Embodiment to a brush, (B) is a perspective view which shows the terminal base material of a power supply side terminal and a brush side terminal. Sectional drawing which shows the fuel pump of 1st Embodiment. (A) is the figure which looked at the holder which removed the end cover in the comparison form of 1st Embodiment from the end cover side, (B) is a B direction arrow directional view of (A). The perspective view which shows the electrical pathway from the power supply side terminal of 2nd Embodiment to a brush.

Explanation of symbols

10: Fuel pump, 12: Pump part, 13: Motor part, 30: Impeller (rotating member), 50: Armature, 54: Commutator, 60: Power supply side terminal, 63: Cut surface, 64: Brush side terminal, 68: Cut surface, 70: Choke coil, 76: Brush, 78: Pigtail, 120: Mold resin, 123, 124: Cut surface

Claims (9)

A pump for boosting the fuel;
An armature that drives the pump unit by rotating;
A commutator installed on one axial side of the armature and rectifying a drive current supplied to the armature;
A brush sliding with the commutator;
A choke coil,
A choke coil connecting portion electrically connected to one end of the choke coil, and a power source side terminal electrically connected to the power source side;
It has a choke coil connection part electrically connected to the other end of the choke coil, is electrically connected to the brush side, and is formed by being cut from a state where it is integrally formed with the power supply side terminal. The brush side terminal,
A fuel pump comprising:   2. The fuel pump according to claim 1, wherein the power supply side terminal and the brush side terminal are installed with their cut surfaces facing each other.   Further comprising a molding resin that covers an electrical connection location between the choke coil and the choke coil connection portion of the power supply side terminal, and an electrical connection location between the choke coil and the choke coil connection portion of the brush side terminal; 3. The fuel pump according to claim 1, wherein the mold resin has a cut surface on the same plane following the cut surfaces of the power supply side terminal and the brush side terminal. 4.   The fuel pump according to claim 3, wherein the mold resin joins two electrical connection portions. A pump for boosting the fuel;
An armature that drives the pump unit by rotating;
A commutator installed on one axial side of the armature and rectifying a drive current supplied to the armature;
A brush sliding with the commutator;
A choke coil connection in which a power supply side terminal electrically connected to the power supply side and a brush side terminal electrically connected to the brush side are integrally formed and electrically connected to the choke coil when a choke coil is used. Electrical terminals provided on the power supply side terminal and the brush side terminal, respectively,
A fuel pump comprising: In a fuel pump manufacturing method in which a pump unit driven by a motor unit boosts fuel,
The power supply side terminal and the brush side terminal of a terminal base material in which a power supply side terminal electrically connected to the power supply side and a brush side terminal electrically connected to the brush side of the motor unit are integrally formed A connection step of electrically connecting the choke coil;
After the connecting step, a cutting step of cutting between the power source side terminal and the brush side terminal of the terminal base material,
After the connecting step, before or after the cutting step, the assembly step of assembling the power supply side terminal and the brush side terminal to the mounting member of the motor unit;
A method for manufacturing a fuel pump, comprising:   The assembly step is performed before the cutting step, and the terminal base material to which the choke coil is electrically connected is assembled to an attachment member of the motor unit in the assembly step. Item 7. A method for manufacturing a fuel pump according to Item 6. A molding step of covering two electrical connection portions of the power supply side terminal and the brush side terminal with the choke coil with a molding resin after the connection step and before the cutting step and the assembly step. Further including
7. The fuel pump according to claim 6, wherein, in the assembling step, the power supply side terminal and the brush side terminal whose electrical connection portions are covered with the mold resin are assembled to an attachment member of the motor unit. Manufacturing method.   9. The method of manufacturing a fuel pump according to claim 8, wherein, in the molding step, the molding resin joins two electrical connection locations.

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