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Development of a Plastic Mold Technology for Bus Ring for DC Brushless Motor

Article of Honda R&D Technical Review Vol.15 No.1


To rationalize the layout and increase the mass productivity of HEV drive motors, integrated molding of high voltage distribution parts using plastic insulation material was investigated as a method to reduce the number of parts and increase ease of assembly. The enlargement of part dimensions occurring with the change to molding plastic from using the former cure coat-type fluoropolymer insulator material was minimized and waterproofing performance was increased. Selection of materials on the basis of measurements of heat strain in plastic molded parts and full molding using floating over molding ensure waterproofing. Study of the design basis for high-voltage insulation clarified the minimum insulation distance, enabling the development of an integrated bus ring molding technology which allows mass production without increasing the dimensions of the parts.


(1) Utsunomiya, T. et al: Dictionary of Electrical Engineering, Tokyo, Gihodo Syuppan Co. Ltd., p. 226 (1988)
(2) Ogawa, H., Fukuda, K.: Development of the Motor for the Civic Hybrid, Honda R&D Technical Review, Vol. 14, No. 2, p. 25-30 (2002)

Author (organization or company)

Kazuo TAKEUCHI(Tochigi R&D Center)、Kotaro TANAKA(Tochigi R&D Center)、Tatsuro HORIE(Tochigi R&D Center)、Akihiro OKAMURA(Tochigi R&D Center)

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