Electronic device and current detector

Abstract

An electronic device and a current detector, as a current sensor of an electronic device, are provided with: a case that houses a plurality of constituent components inside; a magnetic core that is housed inside the case as a constituent component, and that has a gap formed in the middle of a ring-shaped magnetic circuit; a circuit board that is housed inside the case together with the magnetic core, and that has a circuit that detects a detected current using an output signal from a Hall element disposed inside the gap; a gap position rib that is disposed to position the circuit board at a prescribed position in a state of being housed inside the case, the prescribed position being a position that maintains a positional relationship in which the Hall element does not interfere with other constituent components; and a structure of the case and the circuit board that allows the circuit board to be housed inside the case from the outside only in a case where the circuit board passes through a normal path in which the Hall element does not interfere with other constituent components.

Description

TECHNICAL FIELD

[0001] The present application relates to an electronic device having a plurality of constituent components, and a current detector. BACKGROUND

[0002] A current sensor as one of such electronic devices is disclosed, for example, in a publication issued by the Japan Patent Office (JP 2013-068490 A1). The current sensor, when a circuit board is disposed in a case, after disposing a coil in a gap, moves the circuit board along the circumferential direction of a magnetic core, thereby providing a state in which the magnetic core penetrates the coil. Then, the circuit board is rotated around the central axis of the coil, thereby disposing a magnetic sensor in the gap.

[0003] According to the current sensor of the related art, when the plurality of constituent components such as the coil or the magnetic core, the circuit board, and the like are housed in the case as a finished product, there is no need for a special device for winding the coil around the magnetic core, and thus it is considered that the manufacturing cost can be reduced.

[0004] However, in the structure of the related art, complicated steps are required until the magnetic sensor is properly disposed in the gap and the circuit board is housed in the case, and thus there is a problem of poor workability. In addition, during the period until the circuit board is housed in the case, a component such as the coil, which is completely irrelevant to the disposition of the gap, must be temporarily and tentatively disposed in the gap, or the circuit board must be rotated in a direction irrelevant to the assembly position in the case, and thus there is a problem that the coil or the magnetic sensor is interfered with other components in the middle, and is easily damaged. SUMMARY

[0005] An object of the present application is to provide a technology that easily houses a plurality of constituent components in a case without damaging the constituent components. Therefore, the present application adopts the following solution.

[0006] [First Invention]

[0007] First, the present application provides an electronic component. The electronic component of the present application, in addition to having a case that houses a plurality of constituent components therein, has a configuration of a positioning unit and a path restriction unit. The "positioning unit" positions a certain specific constituent component at a prescribed position in a state in which a plurality of constituent components are housed in the case, the prescribed position being a position that maintains a positional relationship in which the certain specific constituent component does not interfere with other constituent components. Thus, in the state of being housed in the case, the plurality of constituent components are in a correct positional relationship, and damage and the like due to interference can be suppressed. However, this is the case in the state of being housed, and in a certain sense, it can be said that it is an inevitable configuration. The problem to be solved by the present application is to achieve ease of housing in the case and to prevent damage to the components.

[0008] Therefore, the present application employs the above-described "pathway restriction unit". When a certain specific constituent component is housed in the case, the "pathway restriction unit" allows the certain specific constituent component to be housed in the prescribed position in the housed state only in the case where the certain specific constituent component is caused to pass through a normal pathway that does not cause interference with other constituent components. Thus, when a specific constituent component among a plurality of constituent components is housed in the case, it is possible to reliably prevent the specific constituent component from causing interference with other constituent components midway through only by the simple step of placing the specific constituent component in the normal pathway.

[0009] On the contrary, the "pathway restriction unit" restricts the housing of a specific constituent component in the case from a pathway other than the normal pathway. Thus, when housed in the case, even if an attempt is made to approach from an erroneous pathway other than the normal pathway, the housing is restricted. Thus, the approach of the specific constituent component to the case becomes a unique normal pathway, and thus it is possible to reliably prevent damage to the constituent components.

[0010] [Second Invention]

[0011] Second, the present application provides a current detector. The current detector of the present application is provided with a case that houses a plurality of constituent components therein, and further provided with a magnetic core, a circuit board, and the like as the plurality of constituent components. The magnetic core has a gap formed midway through a magnetic circuit in a ring shape, and a circuit including a magnetic detection element disposed in the gap in a mounted state is formed in the circuit board.

[0012] Further, the current detector of the present application is provided with the configuration of a "positioning unit" and a "pathway restriction unit". The "positioning unit" causes the circuit board to be positioned at a prescribed position in a state of being housed in the case, the prescribed position being a position that is held in a positional relationship in which interference does not occur between the magnetic detection element and other constituent components (may be the magnetic core, but is not limited thereto). Thus, in the housed state in the case, the circuit board including the magnetic detection element and other constituent components are in a correct positional relationship, and it is possible to suppress damage and the like due to interference. However, this is in the case of the housed state, and in a certain sense, it can be said to be an inevitable configuration. The problem to be solved by the present application is to achieve ease of housing in the case and to prevent damage to the components.

[0013] Therefore, the present application employs the above-described "pathway restriction unit". When the magnetic detection element of the circuit board is housed in the housing, the "pathway restriction unit" allows the magnetic detection element of the circuit board to be housed in the prescribed position in the housed state only in the case where the magnetic detection element of the circuit board is made to pass through the normal pathway that does not cause interference with other constituent members. Thus, when the circuit board including the magnetic detection element among a plurality of circuit boards is housed in the housing, it is possible to reliably prevent the magnetic detection element from causing interference with other constituent members midway through only a simple step of placing the circuit board including the magnetic detection element in the normal pathway.

[0014] On the contrary, the "pathway restriction unit" restricts the circuit board including the magnetic detection element from being housed in the housing from a pathway other than the normal pathway. Thus, when being housed in the housing, even if an attempt is made to approach from an erroneous pathway other than the normal pathway, the housing is restricted. Thus, the approach of the circuit board including the magnetic detection element into the housing becomes the only normal pathway, and thus, damage can be reliably prevented. BRIEF DESCRIPTION OF DRAWINGS

[0015] Figure 1A and Figure 1B is a perspective view showing the assembled state of the current sensor of one embodiment.

[0016] Figure 2 is an exploded perspective view schematically showing the configuration of the current sensor of one embodiment.

[0017] Figure 3 is an exploded perspective view schematically showing the configuration of the current sensor of one embodiment.

[0018] Figure 4A and Figure 4B is a perspective view showing the internal structure of the housing.

[0019] Figure 5A and Figure 5B is a perspective view showing the arrangement of the gap spacers in the housing.

[0020] Figure 6A and Figure 6B is a perspective view showing the arrangement of the magnetic material core (core member) in the housing.

[0021] Figure 7 is a front view showing the arrangement of the magnetic material core housed in the housing.

[0022] Figure 8A and Figure 8B is a cross-sectional view taken along line VIII-VIII of Figure 7

[0023] Figure 9A and​Figure 9B is a perspective view showing the arrangement of the positioning spacer for the magnetic core in the case.

[0024] Figure 10 is a front view showing the arrangement of the positioning spacer housed in the case.

[0025] Figure 11 is an exploded perspective view showing the state in which the positioning spacer is separated from the case and the core member.

[0026] Figure 12 is a sectional view along the XII-XII line in Figure 10

[0027] Figure 13A and Figure 13B is a sectional view along the XIII-XIII line in Figure 10

[0028] Figures 14A to 14C is a sectional view along the XIV-XIV line in Figure 10

[0029] Figure 15A and Figure 15B is a view explaining the positioning of the core member by the positioning spacer.

[0030] Figure 16A and Figure 16B is a perspective view showing the arrangement of the circuit board in the case.

[0031] Figure 17 is a front view of a current sensor including the circuit board.

[0032] Figure 18 is a view showing the circuit board of the current sensor in a state halfway through assembly during the assembly process.

[0033] Figure 19A and Figure 19B is a view showing the circuit board of the current sensor in a state halfway through assembly during the assembly process. DETAILED DESCRIPTION

[0034] Hereinafter, an embodiment of the present application will be described with reference to the drawings. In the following embodiment, a current sensor is exemplified as an example of an electronic device, but the electronic device can be another device. In addition, a magnetic proportional current sensor is exemplified as an example of a current detector, but the present application is not limited thereto, and can be a magnetic balance current sensor, or a fluxgate current sensor.

[0035] Figure 1A and Figure 1B ​​​is a perspective view showing an assembled state of the current sensor 100 of one embodiment. In addition, Figure 2 and Figure 3 is an exploded perspective view schematically showing the configuration of the current sensor 100 of one embodiment. Further, if the current sensor 100 shown in Figure 1A is shown from a different direction (180° opposite side), it becomes Figure 1B a perspective view. In addition, in Figure 2 and Figure 3 , the viewing direction in the perspective view is reversed.

[0036] [Overall Configuration]

[0037] As shown in Figure 2 and Figure 3 , the current sensor 100 mainly includes a case 102, a magnetic core 104, a gap-to-gap spacer 106, a positioning spacer 108, and a circuit board 110, and in a state where the magnetic core 104, the gap-to-gap spacer 106, the positioning spacer 108, and the circuit board 110 are housed in the case 102, it becomes Figure 1A and Figure 1B one use mode. Figures 1A to 3 The current sensor 100 is shown in a posture assuming this use mode, in which it is assumed that an unillustrated conductor (bus bar or the like) through which a detected current flows is inserted in the lateral (horizontal) direction. Further, the current sensor 100 can be used in other postures (for example, a posture in which it is placed horizontally, a posture in which it stands upright, a posture in which it stands upside down, and the like).

[0038] [Case]

[0039] The case 102 has a rectangular container shape in which one end surface is open and the other end surface is closed. In addition, the case 102 is formed with a rectangular through-hole 102a in the center thereof, and thus the container shape of the case 102 as a whole has a rectangular annular shape. The through-hole 102a penetrates the center of the current sensor 100 in the thickness direction in the assembled state, and the above unillustrated conductor is inserted in the through-hole 102a in the lateral (horizontal) direction in the standing posture of the current sensor 100 shown in FIG. 1. Thus, a flange (not shown) for setting the current sensor 100 in the standing posture is integrally formed in the case 102. Further, the internal structure of the case 102 (a plurality of ribs indicated by reference numerals in the drawing) is described later.

[0040] [Core Member, Magnetic Core]

[0041] The magnetic core 104 is annular as a whole in a rectangular shape. The magnetic core 104 is composed of a pair of core members 104a, 104b. The pair of core members 104a, 104b are each in a lateral "U" shape (so-called U-U type), and are arranged in a ring shape in a state in which the two top ends of the "U" are opposed to each other, thereby constituting one magnetic core 104. At this time, a gap 104c is formed between the end faces of the pair of core members 104a, 104b (two portions). The core members 104a, 104b use a soft magnetic material (for example, ferrite, silicon steel, or the like), and a magnetic field generated around the same when a detection current is conducted in a conductor not shown is concentrated to the magnetic core 104. At this time, the magnetic core 104 forms a convergence path of the magnetic field (magnetic circuit, magnetic path, magnetic flux path) in the circumferential direction thereof.

[0042] [holding member]

[0043] The gap-to-gap spacer 106 includes, for example, a thin plate material made of resin. The gap-to-gap spacer 106 is respectively sandwiched and arranged between the gaps 104c of the magnetic core 104. The gap-to-gap spacer 106 holds the gaps 104c at a prescribed interval in a state in which the gap-to-gap spacer 106 is sandwiched between the end faces of the pair of core members 104a, 104b. Specifically, the gap-to-gap spacer 106 can hold the interval of the gaps 104c as a prescribed dimension by a dimension corresponding to the thickness thereof.

[0044] [positioning member]

[0045] The positioning spacer 108 is in a ring shape (a rectangular shape with a hole) that cooperates with the one end face of the case 102 or the side face of the magnetic core 104. In addition, the positioning spacer 108 forms a pair of openings 108a in a plate-shaped portion (not shown) in a ring shape, and forms four leg portions 108b and a locking claw 108c at each of the four corners of the periphery of the plate-shaped portion, and a spring portion 108d at the two opposite side edges. These leg portions 108b or the locking claw 108c, and the spring portion 108d extend from the plate-shaped portion toward the inside of the case 102, and are arranged between the outer peripheral face of the magnetic core 104 and the inner surface of the case 102 in the assembled state of the current sensor 100. Thus, the positioning spacer 108 is housed in the case 102 in a manner in which the one side face and the outer peripheral face of the magnetic core 104 are covered from the one end face opening side of the case 102. In this housed state, the positioning spacer 108 positions the magnetic core 104 at a predetermined position. Further, the positioning by the positioning spacer 108 is described further below.

[0046] [circuit substrate]

[0047] Further, the circuit board 110 also has a shape that matches an end surface of the case 102 or a side surface of the magnetic core 104, but is not connected in a ring shape, and has mounting surfaces that have a "コ" shape that divides a rectangular shape with a hole into halves. Two Hall elements 112 are mounted as magnetic detection elements on one mounting surface through through-holes, and a connector 114 is mounted on the other mounting surface through a through-hole. In the assembled state of the current sensor 100, the circuit board 110 is housed in the case 102 in a manner that it is attached to one side surface of the positioning spacer 108. In this housed state, the two Hall elements 112 are disposed within the gap 104c of the magnetic core 104 through the opening 108a of the positioning spacer 108. A circuit for detecting a detected current using a magnetic detection signal of the Hall element 112 is formed in the circuit board 110. Therefore, various electronic components (chip components, ICs, and the like) that are not shown are mounted on each of the mounting surfaces of the circuit board 110, and various wiring patterns or through-holes are formed in each of the mounting surfaces and the inner layer. Further, the circuit board 110 can be formed in a ring shape.

[0048] [Internal structure]

[0049] Next, the internal structure of the case 102 will be described.

[0050] Figure 4A and Figure 4B are perspective views that show the internal structure of the case 102. In order to facilitate visual confirmation, the direction in which the case 102 is viewed in the perspective views is different in Figure 4A and Figure 4B . Further, in the following description, in order to facilitate, the long dimension direction of the rectangle when viewed from the side of the opening of the end surface of the case 102 in the use mode (the standing posture of FIG. 1) of the current sensor 100 is set as the long side direction (the lateral direction), and the short dimension direction is set as the short side direction (the vertical direction).

[0051] As described above, the case 102 has a through-hole 102a formed in the center, and is surrounded by an inner peripheral wall (not shown) of a rectangular shape around the through-hole 102a. Further, a housing space is surrounded by an outer peripheral wall (not shown) of a rectangular shape that is spaced apart from the inner peripheral wall, and a plurality of ribs are formed on the inner surface of the outer peripheral wall and the outer surface of the inner peripheral wall (the inner side of the case 102). Further, the plurality of ribs each extend in a striped manner from the one end surface of the case 102 toward the other end surface.

[0052] Specifically, first, gap position ribs 102b, 102c each in a pair in the short side direction are formed at a central position in the long side direction. Each of the inner surfaces of the outer peripheral walls opposed in the short side direction is formed with two gap position ribs 102b, and each of the outer surfaces of the inner peripheral walls opposed is formed with two gap position ribs 102c. Further, grooves (not shown) are formed between the gap position ribs 102c of the outer surfaces of the inner peripheral walls.

[0053] Next, intermediate ribs 102e each in a pair in the short side direction are formed on the inner surfaces of the outer peripheral walls at positions spaced apart to some extent from the gap position ribs 102b on both sides in the long side direction. In addition, guide ribs 102d each in a pair in the short side direction are formed on both sides of the intermediate ribs 102e in the long side direction, and guide ribs 102d each in a pair in the short side direction are further formed on both sides of the guide ribs 102d. Further, the intermediate ribs 102e and the guide ribs 102d are formed only on the inner surfaces of the outer peripheral walls.

[0054] The ribs formed on the inner surfaces extending in the long side direction are described above, but ribs are also formed on the inner surfaces extending in the short side direction. Specifically, each of the inner surfaces of the outer peripheral walls opposed in the long side direction is formed with two auxiliary ribs 102f each in a pair. These auxiliary ribs 102f are symmetrically arranged with a space from the central position in the short side direction.

[0055] In addition to the ribs formed on the inner surfaces of the housing 102, several ribs are formed, but the description is omitted for contents particularly irrelevant to the function of the present embodiment.

[0056] Next, the arrangement of the various components in the housing 102 will be described.

[0057] [Arrangement of Gap-to-Gap Spacers]

[0058] Figure 5A And Figure 5B is a perspective view showing the arrangement of the gap-to-gap spacers 106 in the housing 102. Here also, in order to facilitate visual confirmation, the direction of viewing the housing 102 and the like in the perspective view is made different in Figure 5A and Figure 5B . (Hereafter, the same is true.)

[0059] The gap-to-gap spacers 106 are arranged in a state of being inserted between the gap position ribs 102b, 102c each in a pair, and the positions thereof correspond to the positions of the gaps 104c of the magnetic core 104. Further, with respect to the gap position ribs 102c of the inner peripheral walls, one edge portion of the gap-to-gap spacers 106 is fitted in the grooves formed therebetween as described above.

[0060] [Arrangement of Magnetic Core]

[0061] Figure 6A and Figure 6B is a perspective view showing the configuration of the magnetic core 104 (core members 104a, 104b) in the case 102.

[0062] The magnetic core 104 is configured in the case 102 in a state in which the gap inter- spacer 106 is sandwiched between the two core members 104a, 104b with the end faces facing each other. At this time, the core members 104a, 104b are in a state of being housed in the case 102 in a state in which the outer peripheral surfaces are supported (or guided) by the above-mentioned plurality of ribs (gap position ribs 102b, guide ribs 102d, intermediate ribs 102e, auxiliary ribs 102f, etc.). Further, with respect to the inner peripheral surfaces of the core members 104a, 104b, the outer surfaces of the inner peripheral walls of the case 102 support (or guide).

[0063] Here, as already described, the magnetic core 104 is an element that greatly relates to the detection accuracy (characteristics, performance) of the current sensor 100. The characteristics (permeability, hysteresis, etc.) of the material of the magnetic core 104 are self-evident, and in the actual configuration state, it is also extremely important that the gap of the gap 104c is correctly set as prescribed in advance and the end faces of the core members 104a, 104b facing each other across the gap 104c are configured to be directly opposite each other.

[0064] With respect to this point, although it is sufficient to carefully check and manage the gap of the gap 104c or the positional relationship of the end faces to each other one by one by human visual inspection or the like during mass production, it is not realistic to provide such a process in terms of working hours or manufacturing costs. Thus, in reality, the quality is managed on the basis of anticipating a certain degree of deviation, although it is preferable to suppress the deviation to a minimum.

[0065] Therefore, in the present embodiment, various constituent parts are provided with a positioning function, thereby correctly setting the gap of the gap 104c or the positional relationship of the end faces to each other. Hereinafter, the positioning of the core members 104a, 104b will be described.

[0066] Figure 7 is a front view showing the configuration of the magnetic core 104 housed in the case 102. Further, the end surface opening of the case 102 is provided as the front surface (hereinafter, the same applies).

[0067] In this state, a gap 104c is formed between the end faces (two locations) of the core members 104a and 104b. Although the gap spacer 106 is clamped within the gap 104c, it cannot be ensured that the gap spacing DG is the specified size. That is, the reason is that there is a certain degree of positional deviation (gap) between the outer surfaces of each core member 104a and 104b and the inner surface or ribs of the housing 102, in both the long and short directions.

[0068] [Short side direction positioning]

[0069] On the other hand, Figure 7 In the state shown, the two core members 104a and 104b are positioned so that their end faces are correctly aligned with each other at the two locations. This positioning is achieved by positioning the core members 104a and 104b in the short side direction, which is accomplished by the guide rib 102d.

[0070] [Guidance Department]

[0071] Figure 8A and Figure 8B It is along Figure 7 A cross-sectional view of the housing 102 and magnetic core 104 of line VIII-VIII. Figure 8A Showing the entire cross-section, Figure 8B Enlarge and show a portion of it (the area enclosed by the single-dot-dash line).

[0072] As described above, the guide rib 102d extends in a stripe pattern on the inner surface of the outer peripheral wall of the housing 102. However, at the corner between the inner surface of the outer peripheral wall of the housing 102 and the other end face, an inclined guide surface 102g is integrally formed, tapering between the inner surface of the outer peripheral wall and the other end face. This inclined guide surface 102g is located at a position that guides (or supports) the outer periphery of each core member 104a, 104b in its retracted state.

[0073] At this time, each core member 104a and 104b is guided by the inclined guide surface 102g to approach the center in the short side direction and is positioned within the housing 102 along the short side direction. Thus, the opposing end faces of the two core members 104a and 104b are correctly aligned face-to-face. When viewed from between the end faces, the two core members 104a and 104b are aligned along the magnetic flux path formed within the magnetic core 104.

[0074] [Long side direction positioning]

[0075] Next, the positioning along the long side will be explained. Positioning along the long side is achieved by the aforementioned positioning spacer 108.

[0076] Figure 9A and Figure 9B is an exploded perspective view showing the configuration of the positioning spacer 108 with respect to the magnetic core 104 in the case 102.

[0077] As described above, the positioning spacer 108 is housed in the case 102 in a manner of covering from the side surface side of the core members 104a, 104b. In this state, the positioning spacer 108 prevents the core members 104a, 104b from falling out of the case 102, and forms positioning in the long side direction. In addition, the openings 108a of the two portions of the positioning spacer 108 are located at positions passing through the respective gaps 104c.

[0078] Figure 10 is a front view showing the configuration of the positioning spacer 108 housed in the case 102. In addition, Figure 11 is an exploded perspective view showing a state in which the positioning spacer 108 is separated from the case 102 and the core members 104a, 104b.

[0079] As described above, the positioning spacer 108 has the leg portions 108b, the locking claws 108c, and the spring portions 108d. Among them, the leg portions 108b are in a thin plate shape as a whole, and the thickness or width is substantially constant in the insertion direction. The locking claws 108c are in a boss shape in which a "turnback" is formed at the tip end portion. The spring portions 108d are in a pair of leaf spring shapes (clip shapes) in the long side direction, and these pair of spring portions 108d can sandwich the two core members 104a, 104b in the middle and apply a force to the core members 104a, 104b in the opposite direction.

[0080] In the assembly process of the current sensor 100, these leg portions 108b, the locking claws 108c, and the spring portions 108d are inserted between the outer peripheral surfaces of the core members 104a, 104b and the inner surfaces of the case 102 after the core members 104a, 104b are housed. In this insertion process, the leg portions 108b, the locking claws 108c, and the spring portions 108d are sequentially inserted with a time difference, and thus the respective functions are realized.

[0081] Hereinafter, the insertion process will be described.

[0082] [Insertion of leg portions]

[0083] Figure 12 is a cross-sectional view of the case 102 and the positioning spacer 108 (the leg portions 108b) along the XII-XII line in Figure 10

[0084] ​During the insertion of the positioning spacer 108, the tip portions of the leg portions 108b are first inserted along the inner surface of the case 102 and guide the insertion of the positioning spacer 108 at the four corners. Thus, the insertion start position of the positioning spacer 108 with respect to the end face opening of the case 102 can be easily obtained during the assembly of the current sensor 100. Further, at the stage where the tip portions of the leg portions 108b are inserted at the initial stage of the insertion, the other locking claws 108c and the spring portions 108d do not come into contact with the case 102 or the core members 104a, 104b. In addition, the leg portions 108b, although in contact with the inner surface of the case 102, do not come into contact with the core members 104a, 104b even after the completion of the insertion.

[0085] [Insertion of the locking claws]

[0086] Figure 13A and Figure 13B is a cross-sectional view of the case 102, the magnetic core 104, and the positioning spacer 108 (the locking claws 108c) along the XIII-XIII line in Figure 10 Figure 13A shows the state at the initial stage of the insertion, Figure 13B shows the state at the completion of the insertion.

[0087] Figure 13A : At the initial stage of the insertion, the locking claws 108c are inserted after the leg portions 108b, but the locking claws 108c do not particularly function at this stage. Further, the locking claws 108c also do not come into contact with the core members 104a, 104b.

[0088] Figure 13B : On the inner surface of the case 102, a protrusion-shaped locking portion 102h is formed in correspondence with the position where the locking claws 108c are arranged, and the locking claws 108c function together with the locking portion 102h at the final stage of the insertion process. That is, at the final stage of the insertion process, the tip portions (folded-back portions) of the locking claws 108c come into contact with the locking portion 102h and are bent (elastically deformed) toward the core members 104a, 104b. At this time, the insertion start position of the positioning spacer 108 is determined at the initial stage of the insertion process, and thus the management of the bending load and the amount of bending to which the locking claws 108c are subjected can be stabilized.

[0089] After that, if the tip portions (folded-back portions) of the locking claws 108c pass through the locking portion 102h as the insertion proceeds, the locking claws 108c are restored from the bent state, and the tip portions (folded-back portions) are caught by the locking portion 102h. Thus, the positioning spacer 108 is prevented from falling out of the case 102, and the holding of the core members 104a, 104b is performed.

[0090] [Insertion of the spring portions]

[0091] ​Figures 14A to 14C is along Figure 10 is a cross-sectional view of the case 102, the magnetic core 104, and the positioning spacer 108 (spring portion 108d) along the XIV-XIV line in Figure 14A → Figure 14B → Figure 14C The insertion process is performed in this order.

[0092] Figure 14A The spring portion 108d extends in a manner inclined from its base end toward the center direction, but the tip end portion is warped in a direction opposite to the facing direction of the core members 104a, 104b. This warped portion enters the overlapping RP inward of the outer periphery of the core members 104a, 104b when viewed in the long side direction. Therefore, during the insertion process, the warped portion of the spring portion 108d is in a positional relationship in contact with the outer periphery of the core members 104a, 104b.

[0093] Figure 14B If the insertion continues, the spring portion 108d is in contact with the outer periphery of the core members 104a, 104b at the warped portion. Also in this case, the insertion start position of the positioning spacer 108 is determined at the initial stage of the insertion process, so stable management of the bending load and the deflection amount to which the spring portion 108d is subjected can be performed.

[0094] After that, the insertion is further performed, so that the spring portion 108d is pressed by the outer periphery of the core members 104a, 104b and is deflected (elastically deformed) as a whole. At this time, when viewed in both side directions in the long side direction, the spring portion 108d is bent and deformed in a manner expanded outward.

[0095] Figure 14C In the state where the insertion is completed, the spring portion 108d is in a state (shown by a solid line) retaining the bent deformation as it was toward the outside in the long side direction when viewed from the original natural state (shown by a two-dot chain line). At this time, the spring portion 108d exerts a force to the core members 104a, 104b in the facing direction of each other by its restoring force, and the core members 104a, 104b are positioned by the acting force F from the spring portion 108d. Further, in the state where the insertion of the positioning spacer 108 is completed, the spring portion 108d is housed between the auxiliary ribs 102d.

[0096] [Positioning in the long side direction]

[0097] Figure 15A and Figure 15B are diagrams explaining the positioning of the core members 104a, 104b by the positioning spacer 108. Further, Fig. 15 corresponds to a diagram in which the cross section shown in Fig. 14 is extended in the long side direction. Figures 14A to 14C

[0098] ​Figure 15A In the present embodiment, the entire width W2 of the magnetic core 104 is set to be longer than the pitch Wl of the pair of spring portions 108d of the positioning spacer 108 from each other.

[0099] Here, the pitch Wl of the spring portions 108d from each other is the shortest distance between the warped portions of the spring portions 108d as described above. In addition, the entire width W2 of the magnetic core 104 is a length obtained by setting the lengthwise dimension LC of each core member 104a, 104b to a length twice as long as the normal interval DG of the gap 104c. Further, the pitch Wl and the entire width W2 can have a certain degree of tolerance.

[0100] Figure 15B In the state where the positioning spacer 108 is arranged, the force F from the spring portions 108d acts as described above, and the pair of core members 104a, 104b are positioned in the direction opposite to each other by the force and positioned. At this time, the core members 104a, 104b sandwich the gap interval spacer 106 between the opposing end faces, and thus are reliably positioned at the central position in the lengthwise direction. Thus, the gap 104c can be correctly set to the prescribed interval DG.

[0101] [Arrangement of Circuit Substrate]

[0102] Figure 16A and Figure 16B is a perspective view showing the arrangement of the circuit substrate 110 in the case 102.

[0103] As described above, the circuit substrate 110 has an outer shape in which the mounting surface is in a "コ" shape, and is arranged in the case 102 in such a manner as to be attached to the outer surface of the positioning spacer 108 in the assembled state of the current sensor 100. In addition, the magnetic sensing portion (magnetic sensing surface) of the Hall element 112 (in Figure 16A and Figure 16B , Figure 17 (not shown in FIGS. 1 to 3) is arranged in the gap 104c through the opening 108a of the positioning spacer 108.

[0104] Here, in order to cause the Hall element 112 to correctly perform the detection operation in the current sensor 100, it is necessary to correctly position the arrangement of the Hall element 112 (magnetic sensing portion) in the gap 104c. Since the Hall element 112 is mounted to the circuit substrate 110, the position of the Hall element 112 with respect to the circuit substrate 110 can be considered to be constant. Therefore, in the present embodiment, the circuit substrate 110 is normally positioned with respect to the case 102, and thus the position of the Hall element 112 (magnetic sensing portion) in the gap 104c is normally positioned.

[0105] [Positioning of Circuit Substrate]

[0106] Figure 17 This is a front view of the current sensor 100 including the circuit board 110. The circuit board 110 is positioned using the gap position ribs 102b and auxiliary ribs 102f of the housing 102. Therefore, in the circuit board 110, in addition to the cutouts 110a formed at two locations on the outer edge, a cutout 110c is also formed at one location. The positions of the cutouts 110a correspond to the positions of the gap position ribs 102b in the configuration state of the circuit board 110, and the positions of the cutouts 110c correspond to the positions of the auxiliary ribs 102f. Furthermore, a cutout 110b is also formed on the outer edge of the circuit board 110.

[0107] Specifically, two gap position ribs 102b are arranged in each gap 104c along their long side. The corresponding cutout 110a is large enough to accommodate the entire arrangement of the two gap position ribs 102b. Additionally, auxiliary ribs 102f are arranged in two pairs on each side along their long side, but the auxiliary rib 102f corresponding to the cutout 110c is only one of these pairs. Furthermore, the cutout 110c is also large enough to accommodate one corresponding auxiliary rib 102f. Therefore, when the circuit board 110 is housed in the housing 102, two cutouts 110a respectively accommodate the entire arrangement of the gap position ribs 102b, and one cutout 110c accommodates one auxiliary rib 102f, thus the circuit board 110 is properly positioned (at a predetermined position). This allows the Hall element 112 to be positioned in its normal position (positioning unit) within the gap 104c without interference from the core members 104a, 104b, or the gap spacers 106. Alternatively, the auxiliary rib 102f and the incision portion 110c can be omitted.

[0108] [Configuration flexibility]

[0109] The circuit board 110 can be changed to be compatible with Figure 17 The second configuration differs from the first configuration shown. Specifically, the second configuration (not shown) is achieved by rotating the circuit board 110 180° circumferentially from the first configuration along the through hole 102a. In the first configuration, the connector 114 is... Figure 17 In the front view shown, the connector 114 is located in the lower right corner, but in the second configuration, the connector 114 is located in the upper left corner. This allows for the selection of a location that facilitates connection (wiring) to the connector 114, appropriate to the actual operating environment of the current sensor 100.

[0110] Furthermore, in the second configuration, as described above, with the cutout portion 110a in two locations respectively accommodating the entire arrangement of the gap position ribs 102b, the circuit board 110 can be positioned normally.

[0111] As described above, in the state where the circuit board 110 is housed in the case 102 (assembled state), the circuit board 110 is normally positioned so that both the Hall elements 112 are appropriately disposed in the corresponding gaps 104c. As described above, the circuit board 110 containing the Hall elements 112 can be thus normally positioned, and this also contributes to the correct positioning of the core members 104a, 104b.

[0112] However, even if the core members 104a, 104b are correctly positioned in advance, if the circuit board 110 is assembled in the case 102 in an inappropriate path during the assembly process of the current sensor 100 (pre-assembly stage), there is a risk that, for example, the Hall elements 112 interfere with other constituent members. That is, before being housed in the case 102, the circuit board 110 is not positioned, and therefore, for example, it cannot be ensured that the two Hall elements 112 respectively face the corresponding gaps 104c midway through the work of housing the circuit board 110 in the case 102.

[0113] Thus, during the assembly process of the current sensor 100, if the circuit board 110 is to be assembled in a state where the position is not yet determined, the Hall elements 112 that protrude greatly from the mounting surface can come into contact with portions other than the gaps 104c (the outer surface of the positioning spacer 108 or the outer surface of the core members 104a, 104b, etc.), and can be damaged to a considerable extent (deformation such as bending of each lead terminal, breakage of the elements themselves, etc.).

[0114] Of course, in the assembly work, for the purpose of caution, it can be said that the positions of the Hall elements 112, etc. can be carefully adjusted one by one by visual inspection by a person, etc. before the circuit board 110 is assembled during mass production, but it is not realistic to provide such a process in terms of working hours or manufacturing costs.

[0115] Therefore, in the present embodiment, a structure is provided that allows the assembly (housing in a predetermined position) of the circuit board 110 only in a case where the circuit board 110 faces the opening of one end surface of the case 102 in the normal assembly position. Hereinafter, this point will be described.

[0116] [Restriction of housing (1)]

[0117] Figure 18 is a view showing the circuit board 110 in the current sensor 100 during the assembly process in a state halfway through assembly (cross-sectional view along the XVIII-XVIII line). Figure 17

[0118] ​The circuit board 110 is not yet positioned in the normal position before being housed in the case 102, i.e., in the middle of assembly, and moreover, it cannot be ensured that it is certainly aligned with the normal assembly position. In the illustrated example, the circuit board 110 as a whole is displaced from the normal assembly position in the direction of the arrow Al (short side direction) in the drawing, and therefore the center of the Hall element 112 is displaced further in the direction of the arrow Al than the center of the opening 108a.

[0119] In the present embodiment, for example as shown in Figure 18 , even if the circuit board 110 is to be housed in the case 102 in a state in which it is not aligned with the normal assembly position, the circuit board 110 (mounting surface) will come into contact with the edge of the opening of the case 102 at one end and hinder its housing. Moreover, even if the circuit board 110 comes into contact with the edge of the opening of the case 102, since the depth DP from the edge of the opening of the case 102 to the outer surface of the positioning spacer 108 is set to be greater than the mounting height HT of the Hall element 112, the Hall element 112 will not interfere with other constituent members.

[0120] [Allowing housing (1)]

[0121] Furthermore, although not shown, if the circuit board 110 is to be properly housed in the case 102 from the state shown in Figure 18 , the worker or work machine needs to modify the circuit board 110 to a state in which it is aligned with the normal assembly position. Moreover, the circuit board 110 is allowed to be housed in the case 102 only in the case in which the Hall element 112 passes through a path in which it does not interfere with the outer surface of the positioning spacer 108 or the core members 104a, 104b.

[0122] [Restriction of housing (2)]

[0123] Figure 19A and Figure 19B is a view (cross-sectional view along the line XIX-XIX in Figure 18 ) showing the circuit board 110 in the middle of assembly during assembly of the current sensor 100 from a different direction than Figure 17 .

[0124] [Restriction of housing]

[0125] Figure 19AFor example, the circuit board 110 does not face the normal mounting position, even if the circuit board 110 is to be housed in the housing 102 in a state of being positionally deviated in the long side direction of the housing 102 (the direction of the arrow A2 in the drawing), the circuit board 110 (mounting surface) will come into contact with the edge of the opening of the housing 102 at one end and hinder the housing. Also, even if the circuit board 110 comes into contact with the edge of the opening of the housing 102, since the depth DP from the edge of the opening of the housing 102 to the outer surface of the positioning spacer 108 is set to be larger than the mounting height HT of the Hall element 112, the Hall element 112 will not interfere with other constituent members.

[0126] [When housing is permitted (2)]

[0127] Figure 19B Thereafter, if the operator or the work machine makes the circuit board 110 face the normal mounting position, the circuit board 110 is permitted to be housed in the housing 102 only in a case where a normal path toward the mounting position is passed from this state. The housing (mounting work) of the circuit board 110 is permitted only in a case where such a normal path is passed, and thus it is possible to reliably prevent the Hall element 112 from being damaged by interference with the outer surface of the positioning spacer 108 or the core members 104a, 104b.

[0128] Further, the above example is about a case where the circuit board 110 is deviated in an arbitrary one direction (the arrows Al, A2), but a case where the circuit board 110 is deviated in both directions in combination is also similarly restricted from being housed in the housing 102 from this state.

[0129] In any case in the present embodiment, the circuit board 110 is permitted to be housed in the housing 102 only in a case where a normal path in which the Hall element 112 does not interfere with other constituent members is passed during assembly of the current sensor 100. Thus, it is possible to ensure the quality of the completed current sensor 100 without the Hall element 112 being damaged during assembly.

[0130] The current sensor 100 according to the above embodiment can achieve the following advantages.

[0131] (1) In a case where the magnetic core 104 is constituted by a plurality of core members 104a, 104b, although it is difficult to make the gap 104c close to a required value in terms of structure due to a deviation in the positional accuracy of each core member 104a, 104b, in the present embodiment, the two core members 104a, 104b are forced in the direction of facing each other and positioned by the spring portion 108d of the positioning spacer 108, and thus it is possible to maintain the state in which the gap interval is made close to the required value by the gap interval spacer 106 that is sandwiched between the end surfaces.

[0132] (2) The force application and positioning by the positioning spacer 108 after the product is shipped also effectively functions, so even if there is an influence of the use environment of the current sensor 100 (for example, temperature change, etc.), the force from the spring portion 108d acts in a direction to maintain the gap interval to the required value, so it is possible to maintain the detection accuracy for a long period of time.

[0133] (3) The positioning spacer 108 is assembled in a manner of being covered from the outside of the case 102 after the core members 104a, 104b are assembled, so the workability is high, and it is possible to correctly position the core members 104a, 104b by a simple and easy work.

[0134] (4) The positioning spacer 108 has a function of positioning itself to an insertion start position which is open to one end surface of the case 102 (leg portion 108b), so it is possible to stabilize the manner (position or angle) in which the engagement claw 108c or the spring portion 108d comes into contact with the engagement portion 102h or the core members 104a, 104b at the time of assembly. Due to this, it is possible to easily manage the load and the amount of deflection which the engagement claw 108c or the spring portion 108d receives, and it is possible to reliably prevent breakage and the like at the time of assembly work.

[0135] (5) In addition, by merely housing the core members 104a, 104b in the case 102, the guide ribs 102d align the core members 104a, 104b themselves to the central position in the short side direction, so the worker or the work machine does not need to consider positioning one by one, and the workability is further improved.

[0136] (6) When the assembly work of the circuit board 110 (housing in the case 102) is performed, it is possible to restrict assembly from an abnormal and inappropriate path, so the worker or the work machine does not mistakenly damage the electronic components such as the Hall element 112.

[0137] (7) Conversely, even if the worker or the like touches the normal path which allows assembly of the circuit board 110 to perform trial and error, if assembly of the circuit board 110 is allowed, since it is a normal assembly path, the work can be easily and reliably completed even without special attention.

[0138] (8) Due to this, it is possible to improve the production efficiency of the current sensor 100 and achieve cost reduction.

[0139] The present application is not limited to the above-described embodiment, and various modifications can be made and implemented. For example, the overall shape of the current sensor 100 can also be a shape other than a rectangular ring shape. Also, it can be a configuration in which the housing 102 is filled with sealing resin or the like in a state in which the magnetic core 104 or the gap interval member 106, the positioning interval member 108, the circuit board 110, and the like are housed in the housing space. In this case as well, the positioning is effectively performed using the force of the positioning interval member 108, and thus the effects of changes in the volume of the filling resin and the like can be compensated for, and the interval of the gap 104c can be maintained for a long period of time.

[0140] The housing 102 can also be configured in a manner in which it is divided into a plurality of portions, and can be provided with an openable and closable cover. Also, the shape of the housing 102 or the arrangement of the ribs (the gap position ribs 102b, 102c, the guide rib 102d, the intermediate rib 102e, the auxiliary rib 102d, and the like) can be appropriately modified in cooperation with the shape of the core members 104a, 104b used, and the number thereof is not limited to the examples described in the embodiments.

[0141] The magnetic core 104 has the gap 104c at the central position in the longitudinal direction, but can have the gap 104c at another position. Also, the number of gaps 104c can be more than two. In this case as well, the positioning interval member 108 not only exerts a force in the direction in which the gaps 104c face each other but also performs positioning, and thus the intervals of the respective gaps 104c can be appropriately maintained.

[0142] In the embodiments, as one example of the magnetic core 104, a two-piece core member 104a, 104b is described, but a magnetic core in which a plurality of plate-shaped core members are stacked can also be used. In this case, the positioning using the spring portion of the positioning interval member can be configured to exert a force in the direction in which the plate-shaped core members face each other in a state in which they are stacked, and to perform positioning.

[0143] The positioning of the circuit board 110 can also be performed using a configuration other than the fitting of the gap position rib 102b and the cutout portion 110a. For example, a positioning-purpose rib can be formed separately on the housing 102, and a cutout portion corresponding to the rib can be formed on the circuit board 110. Also, a convex portion can be formed protruding from the outer edge of the circuit board 110, and a recess portion capable of housing the convex portion can be formed on the housing 102 and can be configured as a positioning unit. Also, the number of portions to be positioned can be three or more.

[0144] In the above-described embodiment, the current sensor 100 is exemplified as an example of the electronic device, but the present application can also be an electronic device other than the current sensor 100. For example, if it is an electronic device in which a plurality of constituent components are housed in a case, such as an electronic communication device, a portable information terminal, a tablet, a personal computer, a server, a remote controller, and the like, it can be applied to any device. Thus, as an example of the case, in addition to the housing 102, a case applied to the above-described various electronic devices can be exemplified.

[0145] The unit (path restriction unit) that allows housing of the circuit board 110 and the like can also be, for example, a unit realized by a combination of a guide groove and a slide bar, or the like, in addition to the unit exemplified in the embodiment. In this case, it can also be configured that a guide groove that guides the fitting of the circuit board 110 is formed on the inner face of the housing 102, a convex slide bar that is embedded in the guide groove is formed on the circuit board 110, and thus the circuit board 110 is allowed to be housed in the housing 102 (fitting work) only in a case where the slide bar is correctly embedded in the guide groove. In this case, the circuit board 110 is restricted from being housed from a path other than a path along which the slide bar is guided by the guide groove.

[0146] In addition, in the embodiment, the circuit board 110 is positioned at a prescribed position that is a positional relationship in which the Hall element 112 is held so as not to interfere with the positioning spacer 108 or the core members 104a and 104b, but it can also be, for example, a position that holds a positional relationship in which an IC chip other than the Hall element 112 does not interfere with other constituent components. In addition, the constituent components that do not interfere with each other are not limited to the combination of the mounting component of the circuit board 110 and other constituent components, and can also be, for example, the combination of the core members 104a and 104b and the entire circuit board 110, the combination of the connector 114 and the core members 104a and 104b, or the combination of other constituent components that should avoid various interferences with each other.

[0147] In addition, the other constituent components that should avoid interference with the Hall element 112 and the like are not limited to components that are fitted from the outside to the housing 102, and can also be components that are housed inside in a state where the housing 102 (the case) is integrated (not limited to components that must be subjected to fitting work from the outside).

[0148] Furthermore, the structure exemplified together with the drawing in the embodiment and the like is only one example that is preferable, and of course the present application can be appropriately implemented even if various elements are added to the basic structure or a part is replaced.

Claims

1. An electronic device in which a plurality of constituent components are housed in the interior of a case, characterized by comprising: The electronic device includes: a positioning unit that positions a specific component in a state where the specific component is housed in the case at a prescribed position that is a position relationship in which the specific component is held so as not to interfere with other components; a path restriction unit that allows the specific component to be housed in the prescribed position in the case from the outside only in a case where the specific component passes through a normal path in which interference with other components does not occur, the specific component includes a circuit board and a first electronic component mounted to a mounting surface of the circuit board, in a case where the circuit board is housed in the case from a path other than the normal path, the mounting surface contacts an opening edge of the case, and a depth from the opening edge of the case to other components housed in an interior of the case is greater than a mounting height of the first electronic component.

2. The electronic device according to claim 1, wherein the path restriction unit restricts the specific component from being housed in the case from a path other than the normal path.

3. A current detector comprising: a case that houses a plurality of constituent members inside; a magnetic core that is housed in the case as one of the constituent members, and that has a gap formed in the middle of a ring-shaped magnetic path that concentrates a magnetic field generated due to conduction of a current to be detected; and a circuit board that is housed in the case as one of the constituent members together with the magnetic core, and that has a circuit that detects the current to be detected using an output signal from a magnetic detection element disposed in the gap, characterized in that, The current detector includes: a positioning unit configured to position the circuit board in a state where the circuit board is housed in the housing at a prescribed position that is a position relationship in which the circuit board is held so as not to interfere with other components between the magnetic detection element and the other components; and a path restriction unit that allows the circuit board to be housed in the housing from the outside only in a case where the circuit board passes through a normal path in which interference between the magnetic detection element and other components does not occur, the magnetic detection element is mounted to a mounting surface of the circuit board, in a case where the circuit board is housed in the housing from a path other than the normal path, the mounting surface contacts an opening edge of the housing, and a depth from the opening edge of the housing to other components housed in an interior of the housing is greater than a mounting height of the magnetic detection element.

4. The current detector according to claim 3, wherein the path restriction unit restricts the circuit board from being housed in the housing from a path other than the normal path.

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