`
`CERTIFICATION OF TRANSLATION
`
`
`I, Christopher L. Field, residing at 43 Sherman’s Bridge Rd., Wayland
`MA, 01778, United States of America, declare and state as follows:
`
` I
`
` am well acquainted with the English and Japanese languages. I
`have in the past translated numerous Japanese documents of legal
`and/or technical content into English. I am fully accredited by the
`American Translators Association for Japanese to English translation.
`
`To a copy of this Japanese document I attach an English translation
`and my Certification of Translation. I hereby certify that the English
`translation of the document entitled "W097/33359, Motor and Process
`for Producing the Same” is, to the best of my knowledge and ability,
`an accurate translation.
`
` I
`
` further declare that all statements made herein of my own
`knowledge are true, that all statements made on information and
`belief are believed to be true, and that false statements and the like
`are punishable by fine and imprisonment, or both, under Section
`1001 of Title 18 of the United States Code.
`
`Signed,
`
`
`
`
`
`
`
`
`
`June 5, 2017
`_______________
`Date
`
`
`
`
`
`
`
`
`
`
`________________________
`Christopher Field
`
`
`
`Petitioners' Exhibit 1002, pg. 1
`
`

`

`World International Property Organization
`International Bureau
`International application published under the Patent Cooperation Treaty (PCT)
`
`
`(51)
`
`International Patent Classification 6
`H02K 29/00
`A1
`International Publication Number: W097/33359
`(11)
`International Publication Date:
`
`September 12, 1997
`(43)
`International Application Number: PCT/JP 97/00661
`(21)
`International Filing Date:
`
` March 4, 1997
`(22)
`(30) Priority Data
` March 7, 1996
`
`
`Patent Application H8/50633
` March 28, 1996
`
`
`Patent Application H8/73725
`(71) Applicant (For all designated countries except the US)
`
`
`Seiko Epson Corporation [JP/JP]
`
`
`2-4-1 Nishishinjuku, Shinjuku-ku Tokyo 163
`(72)
`Inventors/applicants
`
`
`
`TAKAGI, Kunihiko
`
`
`
`SATO, Michio
`
`
`
`ISHIGURO, Akiyoshi
`TABATA, Kunio
`
`SHINKAWA, Osamu
`Seiko Epson Corporation
`3-3-5 Owa, Suwa-shi, Nagano-ken
`(74) Agent
`
` MORI, Masazumi, Patent Attorney
`
`
`2-9-10 Honcho, Nakano-ku, Tokyo 164 (JP)
`
`(81) Designated Countries: CN, JP, US.
`
`Attached Publication Documents
`
`
`International Search Report
`
` Amendment
`
`JP
`JP
`
`(JP)
`
`(JP/JP)
`(JP/JP)
`(JP/JP)
`(JP/JP)
`(JP/JP)
`
`(JP)
`
`
`
`
`
`(54) Title of Invention Motor and Process for Producing the Same
`
`
`
`(57) Abstract
`
`WO9733359A1 1
`
`Petitioners' Exhibit 1002, pg. 2
`
`

`

`The invention is a motor 1 constituted of a driving system provided with a stator 10 and
`a rotor 14, and with a control system which controls this driving system and has circuit
`boards 21, 22 housed in a case 2, wherein the motor 1 is provided with a first conductive
`pin 25 through which electric current flows to supply power to the control system, and a
`second conductive pin 26 through which electric current output from the control system
`flows to each phase of a coil that is housed within the case 2, and the circuit board is sup-
`ported by the first and second conductive pins. The invention also discloses a method for
`the manufacture of a motor in which a motor stator, metal cylindrical body, and embedded
`members are inserted and affixed, then molten resin is injected into the cavity formed by a
`first mold 101 and a second mold 102 that are joined at a mold split face 104, and a third
`mold 103 which is inserted into the central portion of the first and second molds.
`
`
`SPECIFICATION
`
`
`Motor and Method of Manufacturing Same
`
`This invention relates to a motor which is used as a drive source for a device provided
`with an electric motor such as an electric scooter, electric vehicle, or the like, and also to a
`method for manufacturing same.
`
`Background Art
`
`The development of electric scooters, electric vehicles, and other vehicles that do not
`use internal combustion engines has progressed in recent years. Motors used as drive
`sources for these types of vehicles are housed in metal cases to protect their internal parts.
`These cases comprise a metal case and a cover, and are made of aluminum or the like.
`The case is assembled by covering the case with the cover after installing the constituent
`components of the motor in the case and then bolting the cover to the case. In such
`circumstances, the control system that controls the drive of the motor is provided on the
`exterior of the case.
`The following problems arise, however, in motors constituted in this way because the
`control system is typically provided on the exterior of the case.
`When a motor is installed, for example, in a scooter, the motor installation and control
`system installation must be performed separately. Moreover, the task of installing cables
`correctly between the motor unit and the control system involves additional labor.
`A further problem is that space is required to accommodate the motor, the control
`system, and the connections therebetween because the motor and the control system must
`be installed separately.
`
`WO9733359A1 2
`
`Petitioners' Exhibit 1002, pg. 3
`
`

`

`A particular problem is that additional space is required because a heat dissipation
`component (heat sink) must be provided for the control system that is separate from the
`heat sink for the motor because the control system is also a heat-generating body.
`An additional problem is the tendency for the cables that connect the motor to the
`control system to get damaged during installation into the scooter or when the scooter is in
`motion or the like.
` On the other hand, in place of an assembled metal case, it is conceivable that the entire
`motor could be molded using resin and that this molded resin would serve as the case.
`However, this approach is unsatisfactory because the heat-dissipating characteristics of
`resin are inferior and resin has less mechanical strength.
`
`Thus, this invention proposes a motor that is easy to assemble and install, and that is
`compact and highly reliable, as well a method for the manufacture of this motor.
`
`
`
`
`
`WO9733359A1 3
`
`Petitioners' Exhibit 1002, pg. 4
`
`

`

`Disclosure of the Invention
`
`The invention is a motor constituted by a case housing a drive system comprising a sta-
`tor and a rotor, and a control system having a circuit board for controlling this drive system,
`wherein a first conductive pin through which electric current flows to supply power to the
`control system and a second conductive pin through which electric current output from the
`control system flows to each phase of a coil are housed within the case, and the circuit
`board is supported by the first and second conductive pins.
`
`Thus, the number of components and the mounting space required in the invention is
`reduced compared to systems in which the members for mounting the circuit boards and the
`cables for electrically connecting the power source in the control system are used. Accord-
`ingly, the motor can be made more compact in size. Moreover, the fact that the components
`can be arranged and mounted in one direction lends itself to automated assembly, and
`makes assembly itself easier.
`
`Further, the invention relates to a motor, which comprises a drive system having a stator
`and a rotor, and a control system which controls the drive system and has circuit boards,
`both of which are housed in a case wherein the control system has a board and a plurality of
`switching elements which are arranged in a ring shape and mounted on the board.
`
`Therefore, a plurality of switching elements can be installed in a small space so that the
`circuit board can be made smaller and the control system can be made more compact with-
`out increasing the surge voltage and as a result the motor can be made more compact.
` Moreover, the invention is also a method for the manufacture of a motor in which, us-
`ing a first mold and a second mold joined at a mold split face, and a third mold inserted into
`the center portion of these first and second molds, the motor stator, metal cylindrical body,
`and embedded members are inserted into the cavity formed by these first, second, and third
`molds and affixed, then molten resin is injected to perform resin molding.
`
`Since the motor stator and the like are securely embedded in positions determined by
`the mold, the invention can increase the precision with which pins, circuit boards, and other
`embedded components are assembled. Moreover, since a metal cylinder is provided, the
`strength required at mounting locations and the like can be provided by this cylinder. For
`example, since molding in the formation of connectors is done after wiring the motor drive
`and the sensor wires in the embedded members, there is no need to form a mold split face at
`the location where wiring is pulled out. Thus costs can be reduced because there is no need
`divide the mold in a complicated shape.
`
`Brief Description of the Drawings
`
`FIG. 1 is a cross-sectional side view showing an embodiment in which the motor of the in-
`vention is applied to a motor for an electric scooter.
`
`WO9733359A1 4
`
`Petitioners' Exhibit 1002, pg. 5
`
`

`

`FIG. 2 is a plan view of the motor shown in FIG. 1.
`FIG. 3 is a plan view of the motor in a state with its cover and control system removed.
`FIG. 4 is a bottom view of the motor shown in FIG. 1.
`FIG. 5 is a bottom view of the motor in a state with its lid member and rotor removed.
`FIG. 6 is a bottom view of the motor with its lid member, rotor, and circuit board removed.
`FIG. 7 is a plan view showing a circuit board (first circuit board) and a switching element
`mounted on the circuit board.
`FIG. 8 is a diagram in which affixing members are resin molded parts mounted on the cir-
`cuit board.
`FIG. 9 is a plan view showing a constitutional example of an affixing member.
`FIG. 10 is a plan view showing a state in which switching elements are mounted on the af-
`fixing member shown in FIG. 9.
`FIG. 11 is a cross-sectional view at line A – A in FIG. 10.
`FIG. 12 is a cross-sectional view at line B – B in FIG. 10.
`FIG. 13 is a plan view showing the affixing member shown in FIG. 10 in the installed state
`on the circuit board (first circuit board).
`FIG. 14 is a cross-sectional view along line C – C in FIG. 13.
`FIG. 15 is a bottom view showing a circuit board (second circuit board).
`FIG. 16 is a plan view of a circuit board.
`FIG. 17 is a side view of a circuit board.
`FIG. 18 is a side view showing a constitutional example of an insert nut.
`FIG. 19 is a side view showing the state of wiring applied to insert nuts.
`FIG. 20 is an exploded perspective view showing a constitutional example of a terminal
`member and a connector.
`FIG. 21 is a diagram showing a stator in the state in which wiring is made to the connectors.
`FIG. 22 is an exploded perspective view showing a constitutional example in which the flat
`part of a terminal member is held between a pin and a movable pin.
`FIG. 23 is an exploded perspective view showing another structure example of a terminal
`member and a connector.
`FIG. 24 is a cross-sectional view showing a method of manufacturing the motor of this in-
`vention.
`
`
`Best Mode for Carrying out the Invention
`
`WO9733359A1 5
`
`Petitioners' Exhibit 1002, pg. 6
`
`

`

`The motor and method of its manufacture of this invention will be described in detail
`with reference to preferred embodiments shown in the accompanying drawings. For con-
`venience of description, the lower portion in FIGS. 1, 18, 20, and 24 is referred to as the
`“base end,” while the upper portion is referred to as the “leading end,” and the vertical di-
`rection is the “axial direction.” As shown in FIGS. 1~6, a motor 1 of this embodiment is a
`brushless DC motor which is configured by housing a motor consisting of a stator 10 and a
`rotor 14, and a control system 20 that controls driving of the motor, in a case 2.
`
`In this embodiment, the stator 10 coil (exciting coil) 12 is a three-phase coil constituted
`of a U phase (first phase) V phase (second phase) and W phase (third phase), as will be de-
`scribed below.
`
`The case 2 is comprised primarily of a metal cylinder 3 that is fitted into the outer pe-
`riphery of the stator 10, to be described below, a resin molded part 4, a metal cover 5 that is
`connected to the leading end of the cylinder 3, and a lid member 6 that is mounted onto the
`base end of the resin molded part 4. Of these, the resin molded part 4 is formed by molding
`the cylinder 3 and the stator 10 with a resin. In this case, most of the stator 10 is embedded
`in the resin molded part 4, the leading end and base end of the cylinder 3 are engaged with
`the resin molded part 4 so as to be affixed to the resin molded part 4 so as to be affixed to
`the resin molded part 4.
`
`The resin that constitutes the resin molded part 4 may be either a thermoplastic resin or
`a thermosetting resin. Examples of such resins include rigid resins like polyester-based res-
`ins, phenol-based resins, and urea resins. These resins preferably have a linear coefficient
`of expansion lower than that of the metal configuring the cylinder 3, or as close as possible
`to that of the metal constituting a core 11, and should have excellent absorption of vibration
`and noise, excellent molding properties, and satisfactory strength and durability. In view of
`these points, polyester-based resins are particularly preferable.
` A plurality (six in the drawing) of ribs 31 are formed on the outer periphery of the cyl-
`inder 3 extending in the axial direction. As shown in FIGS. 4~6, the base end of each rib 31
`forms a mount for affixing the brushless DC motor 1 to a scooter body. I.e., a tapped hole
`32 into which a bolt, not shown in the drawing (screw member) is threaded for purposes of
`mounting the brushless DC motor 1 onto a scooter body (not shown in the drawing) is
`formed in the base end of each of the ribs 31. The brushless DC motor 1 is mounted onto
`the scooter body through the mount which is formed on the metal cylinder 3, and the metal
`cylinder 3 is formed with high mechanical strength so that its mounting strength is high and
`the case 2 is not damaged.
`Moreover, a tapped hole 33 is formed on the leading end of each rib 31 is shown in FIG.
`3. A bolt (screw member) 52 is tightened into the tapped hole 33 to connect and affix the
`cover 5 to the cylinder 3. As shown in FIG. 2, the bolts 52 are inserted into a flange 53 that
`is formed on the outer periphery of the cover 5, and the cylinder 3 and cover 5 are connect-
`ed and affixed by threading the respective bolts into their corresponding tapped holes 33.
`
`Further, a pair of grooves 34 is formed to extend in the axial direction on the inner wall
`of the cylinder 3. A conductive rod (primary terminal) is inserted through the grooves 34 to
`
`WO9733359A1 6
`
`Petitioners' Exhibit 1002, pg. 7
`
`

`

`pass through the cylinder 3 from its base end to the leading end and is molded with the res-
`in.
` Conductive rods (primary terminal) 35 are inserted through the grooves 34 to pass
`through the cylinder 3 from its base end to the leading end and are molded with the resin.
`This pair of conductive rods 35 serves as the primary terminal through which current
`flows to the coil 12 of the stator 10 described below, and is specifically a route for supply-
`ing power from a power source (not shown) to the control system 20, which will be de-
`scribed below, and is disposed so as to protrude from the base end of the cylinder 3 further
`toward the base end; in addition, the base ends of the conductive rods 35 are exposed on the
`surface of the resin molded part 4. Here, terminals (connection terminals) 351 that connect
`to a power supply are formed on the base ends of the conductive rods 35; i.e., on the based
`ends of the which are on same side as the protruding end of a rotating shaft, described be-
`low.
`In this way, the brushless DC motor 1 of this embodiment is provided to supply power
`to the control system 20 through the conductive rods 35. Thus, assembly [as in this embod-
`iment] is easier than configurations using cables to supply power from the power supply to
`the control system 20, and damage to the power supply path or cable breakage due to vibra-
`tions and the like can be prevented thereby. Further, there is less power loss compared to
`configurations in which the power supply route is formed with cables.
`Moreover, since the terminals 351 of the conductive rods 35 are disposed on the same
`side as the protruding end of the rotating shaft 15, wiring from the power supply to the ter-
`minals 351 can be performed within the body of the scooter (within the CVT case). Thus,
`the wiring is not exposed on the exterior, thereby protecting the wiring from damage and
`improving its reliability.
`There is no need to provide brushless DC motor 1 with a separate terminal block dis-
`posed between the output side of the power supply and the input side of the control system
`20 to make electrical connections between the power supply and the control system 20.
`Therefore, the brushless DC motor 1 can be made more compact in size.
`An insulating layer 36 is formed between the cylinder 3 and the conductive rods 35 to
`insulate the cylinder 3 from the conductive rods 35. This insulating layer may also be
`formed by means of resin molding.
`The cylinder 3 is made of metal material, for example, aluminum or aluminum alloy,
`copper or copper alloy, stainless steel, or the like. Here, if the cylinder 3 is constituted of
`aluminum or aluminum alloy, the linear expansion coefficient is greater than that of the res-
`in and the core 11. Therefore a gap is provided between the cylinder 3 and the core 11 so
`that when the mold temperature is increased at time of resin molding, as will be described
`below, the molten resin will enter into this gap. When the finished case 22 is cooled, the
`cylinder 3 tends to contract, but since the resin has already entered into [this gap], the con-
`tact pressure between the cylinder 3 and the resin molded part increases without the [cylin-
`der 3] completely contracting. As a result, from the standpoint of firmly affixing the cylin-
`
`WO9733359A1 7
`
`Petitioners' Exhibit 1002, pg. 8
`
`

`

`der 3 to the resin molded part 4, the cylinder 3 is preferably made of aluminum or alumi-
`num alloy.
`Moreover, the conductive rods 35 and the pins 25, 26 to be described below are made of
`copper or copper alloy and preferably made of oxygen-free copper with a view to improv-
`ing motor efficiency.
`As described above, since the cylinder 3 is made of a metal material the resin molded
`part 4 can be reinforced to ensure that the entire case 2 has sufficient strength, while having
`superior heat transfer and heat dissipation properties. The fact that [this constitution] has
`superior heat dissipation properties means that the motor maintains high performance be-
`cause degaussing of the magnets due to motor temperature rise is prevented.
`Heat generated by the driving of the motor is conducted from the stator 10 to the cylin-
`der 3 and a portion of this heat is dissipated into the atmosphere, while the remainder is
`conducted to the cover 5. The cover 5 is positioned to cover the case 2 of the control system
`20, which will be described below. Moreover, this cover 5 is provided with a plurality of
`heat dissipating fins 51 on the leading end thereof, and heat that is transmitted to the cover
`5 is radiated to the atmosphere through these heat dissipating fins 51.
`By providing heat dissipating fins 51 in this way, the surface area of the case 2 is in-
`creased, heat dissipation properties are further enhanced, and the motor and case 2 can be
`cooled efficiently. Particularly when the scooter is in motion, air strikes the surfaces of the
`heat dissipating fins 51 and cools them.
`In this embodiment, an adequate motor cooling effect can be obtained by simply form-
`ing the fins 51 on the cover 5. However, if the cooling effect is insufficient, similar heat
`dissipating fins can be provided on the cylinder 3 as well.
`As described above, the cover 5 of the brushless DC motor 1 also serves as a heat dissi-
`pating part (heat sink), so this constitution has fewer parts and is easier to manufacture than
`constitutions in which the cover and the heat dissipating part are separate members.
`Further, this heat dissipating part serves also as a heat dissipating part for the control
`system 20, as will be described below. I.e., since the motor heat dissipating part and the
`control system 20 heat dissipating part are shared in this embodiment, the brushless DC
`motor 1 can be made compact in size.
` Moreover, when the resin molded part 4 is exposed on the surface, resistance to the en-
`vironment in terms of resistance to water, oil, UV radiation, etc. becomes problematic.
`However, since the cylinder 3 and cover 5 of the brushless DC motor 1 of this embodiment
`are constituted of metal material, when the bass parts of the ribs 31 of the cylinder 3 are
`mounted onto the body of a scooter, the outer periphery thereof is completely covered by
`the metal material. The problem of resistance to the environment can be resolved by using
`such materials as, for example, aluminum mold cast ADC12 or other materials typically
`used for vehicles as the metal material covering the outer periphery [of the brushless DC
`motor 1].
`
`WO9733359A1 8
`
`Petitioners' Exhibit 1002, pg. 9
`
`

`

`The space surrounded by the cover of 5 accommodates the control system 20 for con-
`
`trolling the motor drive. A first configuration example of the control system 20 will be de-
`scribed as follows.
`
`The control system 20 is principally comprised of a circuit board (first circuit board)
`and a circuit board (second circuit board) 22 that are disk-shaped and that are disposed to
`face one another, two electrolytic capacitors 23 that are installed on the base end of the cir-
`cuit board 21, six switching elements (power elements) 24 that constitute an inverter circuit
`that is installed on the leading end of the circuit board 21, an unillustrated inverter control
`circuit (installed on either the circuit board 21 or circuit board 22) that controls the drive of
`the inverter circuit described above, and an unillustrated power supply circuit (installed on
`either the circuit board 21 or circuit board 22).
`
`In this embodiment, a single unit of the switching element 24 is comprised of three
`MOSFETs; the inverter control circuit, following a predetermined energizing pattern (in-
`cluding PWM control), turns on one each of the plus-side switching elements 24 and the
`minus-side switching elements 24 out the six switching elements to sequentially energize
`two [out of the three] phases U, V, and W implementing bipolar driving of the three phases).
`In this way, a rotating magnetic field is formed on the stator 10 to turn the rotor 14.
`
`Each of the switching elements 24 in FIG. 7 are respectively installed on the outer pe-
`riphery part of the leading end of the circuit board 21. Thus, the switching element 24 is
`disposed in the form of a hexagonal ring (substantially circular).
`
`These switching elements 24 have terminal groups (arm parts) 241 that protrude respec-
`tively at one end, and are disposed so they are oriented alternately toward the inner and
`outer circumference thereof. Thus, the switching elements 24 are disposed so that their ter-
`minal group 241 is oriented toward the inner periphery and the switching elements 24 that
`are disposed so that their terminal group 241 is oriented toward the outer periphery alter-
`nate with each other.
`
`Furthermore, a temperature sensor (thermistor) 80 that detects temperature of the
`switching elements 24 is disposed between one of the six switching elements 24 and the
`circuit board 21.
`
`Thus, since the switching elements 24 in the brushless DC motor 1 are disposed in a
`hexagonal ring, the respective lead wires of the circuit board 24 for the U, V, and W phases
`can be made substantially equivalent in length, thereby reducing surge voltage.
` Moreover, since the terminal groups 241 of each of the switching elements 24 are dis-
`posed so as to alternately face the inner and outer circumference thereof, insulation is main-
`tained without the heat dissipating panel coming into contact with adjoining switching ele-
`ments 24. In other words, the switching elements 24 can be installed in a smaller space and
`thus the circuit board 21 can be made smaller in size. Thus, the control system 20 can be
`made more compact in size without an increase in surge voltage, and as a consequence, the
`brushless DC motor 1 can be made more compact in size.
`
`WO9733359A1 9
`
`Petitioners' Exhibit 1002, pg. 10
`
`

`

`Further, since a temperature sensor 80 is provided, the temperature of the heating ele-
`
`ment, namely the switching element 24, can be detected. This increases the accuracy with
`which temperature is detected because the temperature of the switching elements 24 is de-
`tected directly.
`
`Temperature increases of the switching elements 24 are suppressed by controlling the
`drive of the motor according to the value detected by the temperature sensor 80. The relia-
`bility of the brushless DC motor 1 is increased by this control.
` As shown in FIG. 1, the top face (leading end face) of each of the switching elements
`24, which is to say between the top face of each of the switching elements 24 and the inner
`face of the leading end of the cover 5, is provided with a heat dissipating sheet 29 that co-
`vers the entirety of or a portion of the top face.
`
`This heat dissipating sheet 29 is comprised of a material having high thermal conductiv-
`ity, as well as insulating properties and elasticity. Thus, heat from the switching elements
`24 is reliably transmitted to the cover 5 by the heat dissipating sheet 29, thereby enhancing
`cooling efficiency. Moreover, the switching elements 24 and the cover 5 are insulated, and
`the switching elements 24 are thereby protected from damage due to vibration.
`
`The constituent materials of the heat dissipating sheet 29 may be for example, silicates
`such as silicone, mica, clay, talc, or the like; polyethylene terephthalate (e.g. Mylar (prod-
`uct name)); or other types of polyesters.
`
`The heat radiating sheet 29 preferably has a thickness of approximately 0.2-1.0 mm,
`and particularly about 0.4-0.8 mm. When the heat dissipating sheet 29 has a thickness with-
`in this range, the elasticity of the heat dissipating sheet 29 absorbs the assembly discrepan-
`cies in the axial direction that arise when the circuit board 21 is installed onto the pins 25
`and 26 which will be described below, and the switching elements 24 can be securely
`pressed into contact with the cover 5 thereby. Thus, the heat generated by the switching el-
`ements 24 can be more reliably transferred to the cover 5, the insulation between the
`switching elements 24 and the cover 5 can be made more dependable, and damage to the
`switching elements 24 due to vibration and the like can more dependably be prevented.
`
`The following is a description of a second constitutional example of the control system
`20. Shared features with the foregoing first constitutional example of a control system 20
`are omitted here, and the following description will focus primarily on the differences.
` As again shown in FIG. 1, the control system 20 is principally comprised of a disc-
`shaped circuit board (first circuit board) 21 and a disc-shaped circuit board (second circuit
`board) 22 which are disposed to face one another, two electrolytic capacitors 23 which are
`disposed on the base end of the circuit board 21, a stationary member 30 (see FIG. 13), six
`switching elements (power elements) 24 which are disposed on the leading end of the cir-
`cuit board 21 with a stationary member 30 disposed therebetween to configure an inverter
`control circuit (installed on circuit board 21 or 22), and an unillustrated power supply cir-
`cuit (installed on either circuit board 21 or 22).
`
`WO9733359A1 10
`
`Petitioners' Exhibit 1002, pg. 11
`
`

`

` As shown in FIGS. 9 through 14, the stationary member 30 in its entirety is substantial-
`ly a regular hexagonal ring.
`
` A stepped part 302 is provided on each of the six sides of the stationary member 30 po-
`sition the respective switching elements 24, and through holes 304 into which screw mem-
`bers 311 for affixing the stationary member 30 are inserted, are formed on each of the six
`corners 303.
`A mounting part 305 is provided on the inner periphery of one of these sides 301 for the
`installation of a temperature sensor (thermistor) 80 to detect the temperature of the switch-
`ing element 24.
`As shown in FIGS. 10, 11, and 12, the temperature sensor 80 is mounted onto the
`mounting part 305 of the stationary member 30, and the switching element 24 is disposed
`on the respective sides 301. In this way, the switching elements 24 are disposed in a hexag-
`onal (substantially circumferential) ring.
`
`In this case, the switching elements 24 are disposed so that the terminal groups 241 are
`alternately oriented toward the inner and outer circumference. Thus, the switching elements
`24 that are disposed so that their terminal group 241 is oriented toward the inner periphery
`and the switching elements 24 that are disposed so that their terminal group 241 is oriented
`toward the outer periphery alternate with each other.
` As shown in FIGS. 13 and 14, the stationary member 30 is affixed to the outer periph-
`ery at the leading end of the circuit board 21 by the screw members 311. The respective
`switching elements 24 are mounted on the outer periphery of the circuit board 21 with the
`stationary member 30 disposed therebetween.
`
`In this way, the second constitutional example of the control system 20 can be made
`more compact in size without an increase in surge voltage, and as a consequence, the brush-
`less DC motor 1 can be made more compact in size as in the foregoing first constitutional
`example of a control system 20 described above.
`
`Further, in this second constitutional example, efficiency in the assembly process is im-
`proved because the switching elements 24 are installed on the circuit board 21 as a unit and
`with each position at the switching elements 24 determined by the stationary member 30.
`Moreover, wiring can be made simpler and wiring costs reduced in comparison to situations
`in which the switching elements individually installed onto the heatsink using screws in the
`terminal groups of the switching elements are connected to the circuit on the circuit board
`with leads. Moreover cooling efficiency (the radiating effect) can be improved because
`there is no need for tapped holes in the cover 5.
`
`In the same manner as the first constitutional example of the control system 20 de-
`scribed above, a heat dissipating sheet 29 that covers the leading end surfaces of the switch-
`ing elements 24 (between the leading end surfaces of the switching elements 24 and the
`leading end parts of the cover 5) is provided so as to cover these respective leading end sur-
`faces either entirely or in part.
`
`WO9733359A1 11
`
`Petitioners' Exhibit 1002, pg. 12
`
`

`

`In the same way as the first constitutional example described above, cooling efficiency
`
`is improved by the heat dissipating sheet 29. Further, the switching elements 24 and the
`cover 5 are insulated and the switching elements 24 can thus be protected from damage due
`to vibration or the like.
`Since the details of the heat dissipating sheet 29 are the same as in the first constitution-
`al example described above, their description will be omitted here.
`The circuit board 21 and stationary member 30 in this invention may also be formed as
`an integral single unit.
`Further, as shown in FIG. 8, the stationary member 30 may be constituted as a resin
`molded member having the switching element 24 and the temperature sensor 80 molded in
`resin. In this way, the workability of the brushless DC motor 1 can be improved when it is
`assembled.
`
`The following is a description of the connectors.
` As shown in FIGS. 1 and 3, connectors (embedded members) 9, which is to say the
`connector 9U connected to the U phase (first connector), the connector 9V connected to the
`V phase (second connector), and the connector 9W connected to the W phase (third con-
`nector) are embedded in the vicinity of the bearing support part 41 (described below) of the
`resin molded part 4.
`
`The connectors 9U, 9V, and 9W are preferably formed so as to be substantially dis-
`posed on the circumference of the same circle that is centered on the center o