# US 8,785,777 B2 · Actuator control device, and method of manufacturing circuit device in actuator control device

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- Number: US 8,785,777 B2
- Document ID: US8785777B2
- Status: Granted
- Kind: B2
- Application number: 12/976,001
- Filed: 2010-12-22
- Published: 2011-06-30
- Granted: 2014-07-22
- Earliest claimed: 2009-12-25
- Assignees: Hitachi Automotive Systems, Ltd.
- Applicants: Daisuke Yasukawa; Hirofumi Watanabe; Kazuhiko Nakano; Kenji Kikuchi
- Inventors: Daisuke Yasukawa; Hirofumi Watanabe; Kazuhiko Nakano; Kenji Kikuchi
- Web page: https://patentgrep.com/patent/US8785777B2

## CPC

- B60T 8/368: {combined with other mechanical components, e.g. pump units, master cylinders}
- B29C 45/14065: {Positioning or centering articles in the mould}
- B29C 45/14639: {for obtaining an insulating effect, e.g. for electrical components}
- B29C 45/14836: {Preventing damage of inserts during injection, e.g. collapse of hollow inserts, breakage (B29C45/14434 takes precedence)}
- B60T 8/441: {using hydraulic boosters (B60T8/445, B60T8/446, B60T8/447 take precedence)}
- H02M 7/003: {Constructional details, e.g. physical layout, assembly, wiring or busbar connections}
- B29C 2045/14131: {using positioning or centering means forming part of the insert}
- B60T: VEHICLE BRAKE CONTROL SYSTEMS OR PARTS THEREOF; BRAKE CONTROL SYSTEMS OR PARTS THEREOF, IN GENERAL (electrodynamic brake systems for vehicle, in general B60L; brakes per se, i.e. devices where braking effect occurs, including ultimate brake actuators, F16D); ARRANGEMENT OF BRAKING ELEMENTS ON VEHICLES IN GENERAL; PORTABLE DEVICES FOR PREVENTING UNWANTED MOVEMENT OF VEHICLES; VEHICLE MODIFICATIONS TO FACILITATE COOLING OF BRAKES
- B29C: SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING (making preforms B29B11/00; making laminated products by combining previously unconnected layers which become one product whose layers will remain together B32B37/00 - B32B41/00)
- H02M: APPARATUS FOR CONVERSION BETWEEN AC AND AC, BETWEEN AC AND DC, OR BETWEEN DC AND DC, AND FOR USE WITH MAINS OR SIMILAR POWER SUPPLY SYSTEMS; CONVERSION OF DC OR AC INPUT POWER INTO SURGE OUTPUT POWER; CONTROL OR REGULATION THEREOF (transformers H01F; dynamo-electric converters H02K47/00; controlling transformers, reactors or choke coils, control or regulation of electric motors, generators or dynamo-electric converters H02P)

## Abstract

An actuator control device includes a circuit device that is resin-molded by a plurality of metal molds including at least one movable metal mold to include a first bus bar and a second bus bar. The first bus bar and the second bus bar each include a flat plate-like portion that includes two main flat-face portions having large surface areas, and two sub flat-face portions that are adjacent to the main flat-face portions and have smaller surface areas than the surface areas of the main flat-face portions. One of the main flat-face portions of the first bus bar faces one of the main flat-face portions of the second bus bar. The facing direction differs from the mold release direction of the movable metal mold.

## Claims

### Claim 1

An actuator control device, comprising:
a circuit device that is resin-molded by a plurality of metal molds including at least one movable metal mold to include a first bus bar and a second bus bar,
the first bus bar and the second bus bar each including a flat plate-like portion that includes two main flat-face portions with large surface areas, and two sub flat-face portions that are adjacent to the main flat-face portions and have smaller surface areas than the main flat-face portions,
one of the main flat-face portions of the first bus bar and one of the main flat-face portions of the second bus bar being arranged to face each other in a direction that is
substantially perpendicular to a mold release direction of the movable metal mold, and
the first bus bar and the second bus bar including, in a portion in which the main flat-face portions face each other, electric connection terminals connected to one side of the sub flat-face portions adjacent to the main flat-face portions, the electric connection terminals being engaged with a predetermined metal mold at the time of resin molding, and protruding portions provided at the opposite side of the electric connection terminals in the sub flat-face portions adjacent to the main flat-face portions, the protruding portions being engaged with a mold which is different from the predetermined mold at the time of resin molding.

### Claim 2 (depends on 1)

The device according to claim 1, wherein
the first bus bar further includes a first connecting portion that is provided at a portion at which the main flat-face portions face each other, and is connected to a positive-side terminal of a capacitor, the first bus bar being connected to a positive side of a DC power supply, and
the second bus bar further includes a second connecting portion that is provided at a portion at which the main flat-face portions face each other, and is connected to a negative-side terminal of the capacitor, the second bus bar being connected to a negative side of the DC power supply.

### Claim 3 (depends on 1)

The device according to claim 1, wherein
the circuit device is resin-molded by the metal molds including a fixed metal mold and the movable metal mold while the first bus bar and the second bus bar are sealed with resin, and
the protruding portions are engaged with an engaging groove of the movable metal mold.

### Claim 4 (depends on 1)

The device according to claim 1, wherein
the circuit device is resin-molded by the metal molds including a fixed metal mold and the movable metal mold while the first bus bar and the second bus bar are sealed with resin, with a resin plate being interposed between facing portions of the main flat-face portions.

### Claim 5 (depends on 1)

The device according to claim 1, wherein
at least one of the first bus bar and the second bus bar further includes an extension portion that is formed to extend from at least one of two end portions at a length-wise end of the flat plate-like portion and to be bent.

### Claim 6 (depends on 1)

The device according to claim 1, wherein
the facing direction is parallel to an upper face or a lower face of the circuit device, or is horizontal.

### Claim 7

A method of manufacturing a circuit device in an actuator control device, comprising the steps of:
forming a first bus bar and a second bus bar each including a flat plate-like portion that includes two main flat-face portions with large surface areas, and two sub flat-face portions that are adjacent to the main flat-face portions and have smaller surface areas than the main flat-face portions,
supporting the first bus bar and the second bus bar with a plurality of metal molds by supporting electric connection terminals connected to one side of the sub flat-face portions adjacent to the main flat-face portions and protruding portions provided at the opposite side of the electric connection terminals in the sub flat-face portions adjacent to the main flat-face portions, in a portion in which the main flat-face portions face each other, with one of the main flat-face portions of the first bus bar and one of the main flat-face portions of the second bus bar being arranged to face each other in a direction that is substantially perpendicular to a mold release direction of at least one movable metal mold of the metal molds; and
resin-molding the circuit device with the use of the metal molds so that the circuit device includes the first bus bar and the second bus bar.